Professional Documents
Culture Documents
(A099)
SECTIONS
1 FRAME
2 ELECTRICAL SYSTEM
3 DRIVE UNIT
4 STEERING SYSTEM
5 BRAKE/ACCELERATOR SYSTEM
6 HYDRAULIC SYSTEM
10 OPTIONS
12 NUMERICAL INDEX
This Parts Manual is divided into 12 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages
to the corresponding tab.
UNIT CODE A099
11/2018 NORTH AMERICA
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCELERATOR PEDAL ASSEMBLY (MONOTROL) .................................................................................... 5-9
ACCELERATOR PEDAL ASSEMBLY (STANDARD) ..................................................................................... 5-8
ACCUMULATOR ............................................................................................................................................. 10-4
ADD ON OPTION KITS ................................................................................................................................... 11-2
ADD ON TELEMETRY KITS ........................................................................................................................... 11-3
ARMREST SLIDER ASSEMBLY ..................................................................................................................... 1-36
AUXILIARY KEYSWITCH ............................................................................................................................... 10-2
AUXILIARY TUBE EXTENSIONS
THREE STAGE FULL FREE-LIFT - WITHOUT QUICK DISCONNECT FITTINGS ................................... 10-54
THREE STAGE FULL FREE-LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS
.................................................................................................................................................................... 10-56
THREE STAGE FULL FREE-LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ............... 10-58
TWO STAGE FULL FREE- LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ...... 10-64
TWO STAGE FULL FREE-LIFT - WITHOUT QUICK DISCONNECT FITTINGS ....................................... 10-61
TWO STAGE FULL FREE-LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ................... 10-66
TWO STAGE LIMITED FREE LIFT - WITHOUT QUICK DISCONNECT FITTINGS .................................. 10-46
TWO STAGE LIMITED FREE LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS
.................................................................................................................................................................... 10-48
TWO STAGE LIMITED FREE LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS .............. 10-50
B
BACK-UP ALARM ........................................................................................................................................... 10-6
BATTERY COMPARTMENT AND COVERS
HORIZONTAL BATTERY REMOVAL (→ 4/2013) ..................................................................................... 1-38
HORIZONTAL BATTERY REMOVAL (4/2013 →) ..................................................................................... 1-42
VERTICAL BATTERY REMOVAL - E80-120XN (→ 4/2013) ..................................................................... 1-46
VERTICAL BATTERY REMOVAL - E100-120XN (4/2013 →) ................................................................... 1-48
VERTICAL BATTERY REMOVAL - E80-E100XNS WITH STANDARD OVERHEAD GUARD .................. 1-50
VERTICAL BATTERY REMOVAL - E80-E100XNS WITH FLAT OVERHEAD GUARD (→ 4/2013) ......... 1-52
VERTICAL BATTERY REMOVAL - E80-E100XNS WITH FLAT OVERHEAD GUARD (4/2013 →) ......... 1-54
BATTERY CONNECTOR
RAPID CHARGE OPTION .......................................................................................................................... 2-22
WITH FLAT OVERHEAD GUARD - LWB (E100-120XN) (→ 11/2014) ..................................................... 2-13
WITH FLAT OVERHEAD GUARD - LWB (E100-120XN) (11/2014 →) ..................................................... 2-16
WITH FLAT OVERHEAD GUARD - SWB (E80-100XNS) (→ 11/2014) .................................................... 2-18
WITH FLAT OVERHEAD GUARD - SWB (E80-100XNS) (11/2014 →) .................................................... 2-20
WITH STANDARD OVERHEAD GUARD - LWB (E100-120XN) (→ 11/2014) .......................................... 2-7
WITH STANDARD OVERHEAD GUARD - LWB (E100-120XN) (11/2014 →) .......................................... 2-10
WITH STANDARD OVERHEAD GUARD - SWB (E80-100XNS) ............................................................... 2-12
BRAKE ASSEMBLY ........................................................................................................................................ 5-4
BRAKE SYSTEM ............................................................................................................................................. 5-2
C
CARRIAGE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-38
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-28
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-18
DESCRIPTION PAGE
CONTACTOR AND FUSE ASSEMBLY
→ 11/2015 .................................................................................................................................................. 2-24
SEALED (11/2015 →) ................................................................................................................................ 2-26
CONTACTOR ASSEMBLY
UL-E ............................................................................................................................................................ 2-28
UL-EE .......................................................................................................................................................... 2-30
CONTROL PANELS AND CONTACTORS ..................................................................................................... 2-23
CONTROLLER ASSEMBLY
PUMP AND TRACTION (11/2014 →) ........................................................................................................ 2-36
PUMP MOTOR (→ 11/2014) ...................................................................................................................... 2-32
TRACTION MOTOR (→ 11/2014) .............................................................................................................. 2-34
CONVERSION KIT
COUNTERWEIGHT ........................................................................................................................................ 1-4
COUNTERWEIGHT COVER
WITH RAPID CHARGE OPTION ................................................................................................................ 1-5
D
DASH AND STEERING COLUMN COVERS
FIXED COLUMN ......................................................................................................................................... 1-56
TELESCOPIC COLUMN ............................................................................................................................. 1-58
DC CONVERTER
PRIMARY AND AUXILIARY ........................................................................................................................ 10-14
DIFFERENTIAL ASSEMBLY
WET BRAKE ............................................................................................................................................... 3-23
DISPLAY
LOW MOUNT .............................................................................................................................................. 2-48
DISPLAY GROUP AND HARNESS
HIGH MOUNT ............................................................................................................................................. 2-46
DRIP SHIELD AND STATIC STRAP ............................................................................................................... 1-13
DRIVE AXLE AND ATTACHING PARTS ........................................................................................................ 3-2
DRIVE AXLE ASSEMBLY
WET BRAKE - RIGHT AND LEFT HAND HUBS (→ 2/2015) .................................................................... 3-4
WET BRAKE - RIGHT AND LEFT HAND HUBS (2/2015 →) .................................................................... 3-8
WET BRAKE - BRAKES AND DIFFERENTIAL (→ 2/2015) ...................................................................... 3-12
WET BRAKE - BRAKES AND DIFFERENTIAL (2/2015 →) ...................................................................... 3-16
WET BRAKE - INPUT PINION CARRIER (→ 2/2015) ............................................................................... 3-19
WET BRAKE - INPUT PINION CARRIER (2/2015 →) ............................................................................... 3-21
DRIVE TIRE AND WHEEL
E100-120XN ................................................................................................................................................ 3-26
E80XN-100XNS .......................................................................................................................................... 3-25
E
ELECTRICAL ARRANGEMENT ..................................................................................................................... 2-4
F
FENDERS ....................................................................................................................................................... 1-12
FIRE EXTINGUISHER .................................................................................................................................... 10-10
FLOORPLATES AND STEPS ......................................................................................................................... 1-10
FORKS
OPTIONAL LATCH ..................................................................................................................................... 1-63
DESCRIPTION PAGE
POLISHED FORK WITH FULL BOTTOM TAPER - CLASS III AND CLASS IV ......................................... 1-62
POLISHED FULL BOTTOM TAPER OPTIONAL - CLASS III AND CLASS IV ........................................... 1-66
STANDARD TAPER CLASS III AND CLASS IV ......................................................................................... 1-60
FORKS WITH LEVER
STANDARD TAPER OPTIONAL - CLASS III AND CLASS IV .................................................................... 1-64
FREE-LIFT
THREE STAGE FULL FREE-LIFT (→ 10/2013) ........................................................................................ 8-26
THREE STAGE FULL FREE-LIFT (10/2013 →) ........................................................................................ 8-30
FREE-LIFT CYLINDER
THREE STAGE FULL FREE LIFT .............................................................................................................. 8-34
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-18
FULL SUSPENSION SEAT
MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON SWIVEL - SHEET 1 OF 4 ...................... 1-28
RECLINER AND DAMPER KITS - SHEET 2 OF 4 ..................................................................................... 1-30
SERVICE KITS FOR NON SWIVEL AND SWIVEL - SHEET 3 OF 4 ......................................................... 1-32
H
HEADER HOSE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-42
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-22
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-20
HOOD
WITH FLAT OVERHEAD GUARD - AND SHORT WHEEL BASE (E80-100XNS) ..................................... 1-18
WITH FLAT OVERHEAD GUARD - AND LONG WHEEL BASE (E100-120XN) ........................................ 1-20
WITH STANDARD OVERHEAD GUARD - AND SHORT WHEEL BASE (E80-100XNS) .......................... 1-14
WITH STANDARD OVERHEAD GUARD - AND LONG WHEEL BASE (E100-120XN) ............................. 1-16
HYDRAULIC MOTOR ASSEMBLY
WITH 29 CC PUMP (11/2014 →) ............................................................................................................... 6-20
HYDRAULIC CONTROL VALVE
INLET SECTION - MANUAL HYDRAULIC ................................................................................................. 6-36
INLET SECTION - ELECTRO-HYDRAULIC ............................................................................................... 6-44
LIFT, TILT, AND AUXILIARY - MANUAL HYDRAULIC .............................................................................. 6-34
LIFT, TILT, AND AUXILIARY - ELECTRO-HYDRAULIC ............................................................................ 6-42
HYDRAULIC CONTROL VALVE AND FITTINGS
ELECTRO-HYDRAULIC - THREE AND FOUR FUNCTION ....................................................................... 6-38
MANUAL HYDRAULIC - THREE AND FOUR FUNCTION ......................................................................... 6-29
HYDRAULIC CONTROL VALVE ASSEMBLY
ELECTRO-HYDRAULIC - THREE AND FOUR FUNCTION ....................................................................... 6-40
MANUAL HYDRAULIC - THREE AND FOUR FUNCTION ......................................................................... 6-31
HYDRAULIC HOSES
STEERING .................................................................................................................................................. 6-8
HYDRAULIC MOTOR ASSEMBLY
→ 11/2014 .................................................................................................................................................. 6-16
WITH 33 CC PUMP (11/2014 →) ............................................................................................................... 6-22
HYDRAULIC PUMP
29 CC (11/2014 →) .................................................................................................................................... 6-12
33 CC .......................................................................................................................................................... 6-14
HYDRAULIC PUMP AND MOTOR MOUNTING
WET SPLINE DRIVE 29 CC (11/2014 →) ................................................................................................. 6-10
DESCRIPTION PAGE
WET SPLINE DRIVE 33 CC ....................................................................................................................... 6-11
HYDRAULIC SUPPLY AND RETURN
PAGE 1 OF 2 .............................................................................................................................................. 6-2
PAGE 2 OF 2 .............................................................................................................................................. 6-4
HYDRAULIC TANK AND ATTACHING PARTS .............................................................................................. 6-6
I
IMPACT SENSOR ........................................................................................................................................... 10-12
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-14
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-4
INNER MAST AND FREE-LIFT
TWO STAGE FULL FREE-LIFT (→ 10/2013) ............................................................................................ 9-6
TWO STAGE FULL FREE-LIFT (10/2013 →) ............................................................................................ 9-10
INTEGRAL SIDE-SHIFT ASSEMBLY
THREE STAGE FULL FREE-LIFT - E80XN ............................................................................................... 10-32
TWO AND THREE STAGE FULL FREE-LIFT - E100-120XN/E100XNS ................................................... 10-36
TWO STAGE FULL FREE-LIFT - E80XN ................................................................................................... 10-26
TWO STAGE LIMITED FREE LIFT CLASS III - ORFS FITTINGS ............................................................. 10-16
TWO STAGE LIMITED FREE LIFT CLASS IV - ORFS FITTINGS ............................................................. 10-18
INTEGRAL SIDE-SHIFT CARRIAGE
1067 MM (42 IN.) CLASS III - THREE STAGE FULL FREE-LIFT .............................................................. 10-40
THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III .............................................................. 10-34
THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV (→ 11/2016) ........................................ 10-42
THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV (11/2016 →) ........................................ 10-44
TWO STAGE FULL FREE-LIFT - 1067 MM (42 IN.) CLASS III .................................................................. 10-28
TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III .................................................................. 10-30
TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV ................................................................. 10-38
TWO STAGE LIMITED FREE-LIFT - 1067 MM (42 IN.) CLASS III ............................................................ 10-20
TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS III ............................................................ 10-22
TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS IV ............................................................ 10-24
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-10
L
LIGHTS ............................................................................................................................................................ 2-50
LOAD BACKREST EXTENSION ..................................................................................................................... 1-68
M
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-18
TWO STAGE LIMITED FREE-LIFT (→ 10/2013) ...................................................................................... 7-6
TWO STAGE LIMITED FREE-LIFT (10/2013 →) ...................................................................................... 7-10
MAIN LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-22
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-14
TWO STAGE LIMITED FREE-LIFT - E80XN .............................................................................................. 7-14
TWO STAGE LIMITED FREE-LIFT - E100-120XN/E100XNS .................................................................... 7-16
MANUAL CONTROL LEVERS ........................................................................................................................ 6-26
MASTER CYLINDER ...................................................................................................................................... 5-7
DESCRIPTION PAGE
MINI-LEVER CONTROLS
3 FUNCTION ............................................................................................................................................... 2-54
4 FUNCTION ............................................................................................................................................... 2-58
MIRROR
PANORAMIC ............................................................................................................................................... 10-9
MIRRORS ........................................................................................................................................................ 10-8
N
NAMEPLATES AND LABELS
HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-74
SHEET 1 OF 2 ............................................................................................................................................ 1-70
SHEET 2 OF 2 ............................................................................................................................................ 1-72
O
OPERATOR MODULE .................................................................................................................................... 1-2
OUTER MAST
THREE STAGE FULL FREE-LIFT (→ 10/2013) ........................................................................................ 8-2
THREE STAGE FULL FREE-LIFT (10/2013 →) ........................................................................................ 8-6
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-2
OUTER MAST AND MAIN LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-2
OVERHEAD GUARD
FLAT ............................................................................................................................................................ 1-8
STANDARD ................................................................................................................................................. 1-6
P
PARKING BRAKE VALVE ............................................................................................................................... 5-6
POWER CABLES
E100-120XN (→ 11/2014) .......................................................................................................................... 2-42
E100-120XN (11/2014 →) .......................................................................................................................... 2-44
E80-100XNS (→ 11/2014) ......................................................................................................................... 2-38
E80-100XNS (11/2014 →) ......................................................................................................................... 2-40
R
REAR DRIVE HANDLE ................................................................................................................................... 10-11
REPAIR KITS .................................................................................................................................................. 11-4
S
SEAT ATTACHING PARTS
NOT INCLUDED WITH SEAT - SHEET 4 OF 4 .......................................................................................... 1-34
SEATS
NON SUSPENSION - WITH HIP RESTRAINTS ......................................................................................... 1-22
NON SUSPENSION - LOW PROFILE WITH HIP RESTRAINTS ............................................................... 1-26
STEER AXLE
WITHOUT SENSOR ................................................................................................................................... 4-2
STEER AXLE CYLINDER ............................................................................................................................... 4-6
STEER PUMP ASSEMBLY
→ 11/2014 .................................................................................................................................................. 4-16
11/2014 → .................................................................................................................................................. 4-18
STEER TIRE AND WHEEL ............................................................................................................................. 4-8
DESCRIPTION PAGE
STEERING ACCUMULATOR ......................................................................................................................... 4-20
STEERING COLUMN ASSEMBLY
FIXED (→ 10/2013) .................................................................................................................................... 4-11
FIXED (10/2013 →) .................................................................................................................................... 4-12
TELESCOPIC (→ 10/2013) ........................................................................................................................ 4-14
TELESCOPIC (10/2013 →) ........................................................................................................................ 4-15
STEERING WHEEL AND COLUMN
FIXED .......................................................................................................................................................... 4-9
TELESCOPIC .............................................................................................................................................. 4-10
T
TAIL LIGHT MOUNTING ................................................................................................................................. 10-7
TILT CYLINDER .............................................................................................................................................. 6-48
TILT CYLINDER AND ATTACHING PARTS ................................................................................................... 6-46
TILT SENSOR GROUP ................................................................................................................................... 2-61
TRACTION MOTOR ........................................................................................................................................ 3-24
TRACTION SPEED LIMITER
STANDARD AND INTEGRAL SIDE-SHIFT CARRIAGES .......................................................................... 2-62
V
VEHICLE SYSTEM MANAGER ...................................................................................................................... 2-64
W
WIRE HARNESS
EMERGENCY DISCONNECT .................................................................................................................... 2-72
FRONT SWITCH ......................................................................................................................................... 2-73
FRONT SWITCH ......................................................................................................................................... 10-70
INTERFACE FRONT/REAR LIGHTS .......................................................................................................... 10-69
JUMPER, REAR GRAB HANDLE ............................................................................................................... 2-169
LEFT HAND - WITHOUT TURN SIGNALS (10/2013 →) ........................................................................... 2-76
LIGHTS - LEFT HAND (→ 10/2013) .......................................................................................................... 2-74
MAIN - MANUAL HYDRAULIC SHEET 1 OF 3 (→ 11/2014) .................................................................... 2-78
MAIN - MANUAL HYDRAULIC SHEET 2 OF 3 (→ 11/2014) .................................................................... 2-82
MAIN - MANUAL HYDRAULIC SHEET 3 OF 3 (→ 11/2014) .................................................................... 2-86
MAIN - MANUAL HYDRAULIC SHEET 1 OF 3 (11/2014 ↔ 11/2015) ...................................................... 2-90
MAIN - MANUAL HYDRAULIC SHEET 2 OF 3 (11/2014 ↔ 11/2015) ...................................................... 2-94
MAIN - MANUAL HYDRAULIC SHEET 3 OF 3 (11/2014 ↔ 11/2015) ...................................................... 2-98
MAIN - MANUAL HYDRAULIC SHEET 1 OF 3 (11/2015 →) .................................................................... 2-102
MAIN - MANUAL HYDRAULIC SHEET 2 OF 3 (11/2015 →) .................................................................... 2-104
MAIN - MANUAL HYDRAULIC SHEET 3 OF 3 (11/2015 →) .................................................................... 2-108
MAIN - ELECTRO-HYDRAULIC SHEET 1 OF 3 (→ 11/2014) .................................................................. 2-112
MAIN - ELECTRO-HYDRAULIC SHEET 2 OF 3 (→ 11/2014) .................................................................. 2-116
MAIN - ELECTRO-HYDRAULIC SHEET 3 OF 3 (→ 11/2014) .................................................................. 2-120
MAIN - ELECTRO-HYDRAULIC SHEET 1 OF 3 (11/2014 ↔ 11/2015) .................................................... 2-124
MAIN - ELECTRO-HYDRAULIC SHEET 2 OF 3 (11/2014 ↔ 11/2015) .................................................... 2-128
MAIN - ELECTRO-HYDRAULIC SHEET 3 OF 3 (11/2014 ↔ 11/2015) .................................................... 2-132
MAIN - ELECTRO-HYDRAULIC SHEET 1 OF 3 (11/2015 →) .................................................................. 2-136
MAIN - ELECTRO-HYDRAULIC SHEET 2 OF 3 (11/2015 →) .................................................................. 2-140
MAIN - ELECTRO-HYDRAULIC SHEET 3 OF 3 (11/2015 →) .................................................................. 2-144
MAIN CHASSIS - W/O LIGHTS .................................................................................................................. 2-156
DESCRIPTION PAGE
MAIN LIGHTS CHASSIS - 48V ................................................................................................................... 2-148
MAIN LIGHTS CHASSIS - 80V ................................................................................................................... 2-152
MANUAL INTERLOCK ................................................................................................................................ 2-158
RH LIGHT WITH FREEZER DISPLAY - WITH TURN SIGNALS-HIGH MOUNT (10/2013 →) ................. 2-70
RH LIGHT WITH FREEZER DISPLAY - WITH TURN SIGNALS-LOW MOUNT (10/2013 →) .................. 2-71
RH LIGHT WITH STANDARD DISPLAY - WITHOUT TURN SIGNALS-HIGH MOUNT (10/2013 →) ...... 2-66
RH LIGHT WITH STANDARD DISPLAY - WITHOUT TURN SIGNALS-LOW MOUNT (10/2013 →) ....... 2-67
RH LIGHTS - STANDARD OPTION (→ 10/2013) ..................................................................................... 2-65
RH LIGHTS - FREEZER OPTION (→ 10/2013) ........................................................................................ 2-68
SEAT - MANUAL HYDRAULIC ................................................................................................................... 2-159
SEAT - MANUAL HYDRAULIC WITH SEAT BELT SEQUENCE MODULE ............................................... 2-160
SEAT - E-HYDRAULIC ............................................................................................................................... 2-162
SEAT - E-HYDRAULIC WITH SEAT BELT SEQUENCE MODULE ........................................................... 2-164
STEERING COLUMN ................................................................................................................................. 2-166
SYNCHRONOUS STEERING ..................................................................................................................... 2-168
Listed below are abbreviations used in parts manuals to denote the following expressions:
spacer
TERM DEFINITION TERM DEFINITION
Amp Amperes FRE Freezer Environment
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 millimeters
CRE Corrosive Environment MSTS Microprocessor Spark Timing System
D/B Date Break NPT National Pipe Threads
dbA Decibel "A" Scale O/S Oversize
DE Drive End PTO Power Take Off
ECH Empty Container Handler RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High S/N Serial Number
Stacking TMM Truck Management Module
ECH-4 Empty Container Handler - 4 High UL Type D Diesel-Powered Safety Rating
Stacking
UL Type DS Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High
Stacking UL Type E Battery-Powered Safety Rating
This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.
(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.
The letters "I", "O", and "Q" will not be used.
For pending serial numbers contact your local dealer for Hyster lift trucks.
Parts referred to in this book as right or left hand parts are in accordance with the illustration above.
(1) and (2) The first letter and number indicates the mast unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the mast.
(5) Carriage travel in millimeters stamped just below the serial number.
Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).
For pending production sequence numbers contact your local dealer for Hyster lift trucks.
(1) and (2) The first letter and three numbers indicate the attachment unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number.
For pending production sequence numbers contact your local dealer for Hyster lift trucks.
Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify
the attachment.
Always refer to the group, serial, or part number when ordering service parts.
Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are
identified by a model prefix code beginning with the letter "S". Contact your dealer for Hyster lift trucks for information
on these assemblies.
PUBLICATIONS
Every new lift truck is provided with an OPERATING MANUALS with complete replacement part
MANUAL. This manual has information that the identification, are available at a nominal fee from your
operator must know for inspection and operation of the Hyster dealer to assist users in effectively maintaining
lift truck. Hyster lift trucks in a safe, useful condition. See the list
below for information on ordering specific publications
SERVICE MAINTENANCE MANUALS, which provide for this model lift truck.
service and overhaul procedures, and PARTS
1 FRAME
UNIT CODE A099
11/2018 NORTH AMERICA
SECTION 1
FRAME
DESCRIPTION PAGE
OPERATOR MODULE
ITEM PART NO. DESCRIPTION QTY
1 4040909 Cowl .................................................................................................................... 1
2 1528889 Capscrew ............................................................................................................ 2
3 4040030 Side Plate Wldmt (RH) ........................................................................................ 1
4 1530243 Insert ................................................................................................................... 6
5 1698633 Capscrew ............................................................................................................ 6
6 4040388 Bulkhead Weldment ............................................................................................ 1
7 1690977 Capscrew ............................................................................................................ 4
8 1370949
1528888 Nut (Shoulder) .................................................................................................... 6
9 4040021 Side Plate Wldmt (LH) ........................................................................................ 1
10 1527888 Capscrew ............................................................................................................ 2
11 1698799 Plug (Yellow) (0.26 in) ........................................................................................ 2
KEY:
A: E80XN
B: E100XN
C: E120XN/E100XNS
QTY
ITEM PART NO. DESCRIPTION A B C
1 4001816 Counterweight (Light) ........................................................................ 1 1 ..
1 4001817 Counterweight (Heavy) ...................................................................... .. .. 1
2 326347 Tow Pin ............................................................................................. 1 1 1
3 293695 Capscrew .......................................................................................... 2 2 ..
3 1474537 Capscrew .......................................................................................... .. .. 2
4 296426 Washer .............................................................................................. 4 4 4
5 4627358 Nut ..................................................................................................... 2 2 2
6 4615709 Counterweight ................................................................................... 1 .. 1
6 4615710 Counterweight ................................................................................... .. 1 ..
7 1597479 Capscrew .......................................................................................... 2 2 2
8 1308451 Capscew ............................................................................................ 2 2 2
9 296434 Washer .............................................................................................. 4 4 4
10 2311349 Shim .................................................................................................. 1 1 1
FOOTNOTES:
a Not Illustrated c 10/2013 →
b → 10/2013
OVERHEAD GUARD
STANDARD
KEY:
A: Short Wheel Base (E80-100XNS)
B: Long Wheel Base (E100-120XN)
QTY
ITEM PART NO. DESCRIPTION A B
1 4040327
4097637 Overhead Guard (91 in.) ............................................................................ 1 ..
1 4040328
4097635 Overhead Guard (91 in.) ............................................................................ .. 1
1 4040329
4097638 Overhead Guard (94 in.) ............................................................................ 1 ..
1 4040330
4097636 Overhead Guard (94 in.) ............................................................................ .. 1
1 1337087 Flange .................................................................................................... 10 10
2 1586790 Capscrew ................................................................................................... 8 8
3 1530243 Insert .......................................................................................................... 2 2
4 1676884 Handle ........................................................................................................ 1 1
5 1586627 Capscrew ................................................................................................... 2 2
6 1698801 Plug (Yellow) (0.53 in) ................................................................................ 14 14
7 1398009 Plug (Hole) ................................................................................................. 2 2
8 4601386 Grommet .................................................................................................... 7 7
9 1698799 Plug (Yellow) (0.26 in) (Hole) ..................................................................... 4 4
10 1687924 Display Cover Assembly (FFigure 2-22)................................................... 1 1
11 1704669 Screw ..................................................................................................... 4 4
12 1510126 Screw (Button Head) .................................................................................. 2 2
OVERHEAD GUARD
FLAT
KEY:
A: Short Wheel Base (E80-100XNS)
B: Long Wheel Base (E100-120XN)
QTY
ITEM PART NO. DESCRIPTION A B
1 4040331 Overhead Guard (87in.) ............................................................................. 1 ..
1 4040332 Overhead Guard (87in.) ............................................................................. .. 1
2 1586790 Capscrew ................................................................................................... 8 8
3 1530243 Insert .......................................................................................................... 2 2
4 1676884 Handle ........................................................................................................ 1 1
5 1586627 Capscrew ................................................................................................... 2 2
6 1698801 Plug (Yellow) (0.53 in) ................................................................................ 10 10
7 1398009 Plug (Hole) ................................................................................................. 2 2
8 4601386 Grommet .................................................................................................... 5 5
9 1363916 Plug (Hole) ................................................................................................. 4 4
10 1698800 Plug (Yellow) (0.39 in) ................................................................................ 2 2
11 1702413 Plug (Yellow) (0.91 in) ................................................................................ 1 1
12 1687924 Display Cover Assembly (FFigure 2-22)................................................... 1 1
13 1704669 Screw ..................................................................................................... 4 4
14 1510126 Screw (Button Head) .................................................................................. 2 2
KEY:
A: E80XN Wide Tread Tires
B: E100-120XN and E100XNS Standard Tread Tires
C: E100-120XN and E100XNS Wide Tread Tires
QTY
ITEM PART NO. DESCRIPTION A B C
1 1527888 Capscrew .......................................................................................... 6 6 6
2 4005279 Fender (RH) ...................................................................................... 1 .. ..
2 4005280 Fender (RH) ...................................................................................... .. 1 ..
2 4005281 Fender (RH) ...................................................................................... .. .. 1
3 1370949
1528888 Nut (Shoulder) ................................................................................... 6 6 6
4 4005276 Fender (LH) ....................................................................................... 1 .. ..
4 4005277 Fender (LH) ....................................................................................... .. 1 ..
4 4005278 Fender (LH) ....................................................................................... .. .. 1
a b 1581079 Plug ................................................................................................... 4 .. ..
FOOTNOTES:
a For Use with E80XN Models with Standard Tread b Not Illustrated
Tires
KEY:
A: E100-120XN (LWB)
B: E80-100XNS (SWB)
QTY
ITEM PART NO. DESCRIPTION A B
1 4611041 Drip Shield .................................................................................................. 1 ..
1 4611040 Drip Shield .................................................................................................. .. 1
2 1510113 Capscrew ................................................................................................... 4 4
3 1382472
1502543 Nut .............................................................................................................. 2 2
4 1480237 Nut (Fold Over) .......................................................................................... 2 2
5 216895 Static Strap ................................................................................................. 1 1
5 4176452 Static Strap (Loop Style) ............................................................................ 1 1
6 1527884 Capscrew ................................................................................................... 1 1
6 a 1527885 Capscrew ................................................................................................... 1 1
7 296381 Washer ....................................................................................................... 1 1
7 a 15909 Lockwasher ................................................................................................ 1 1
8 1460477 Nut .............................................................................................................. 1 1
8 a 302401 Locknut ....................................................................................................... 1 1
a 1334790 Washer ....................................................................................................... 1 1
FOOTNOTES:
a With Loop Style Strap
KEY:
A: UL-E
B: UL-EE
QTY
ITEM PART NO. DESCRIPTION A B
1 4000457 Hood ........................................................................................................... 1 1
2 2027940 Plug ............................................................................................................ 4 4
3 1661162 Handle (Hood) ............................................................................................ 3 3
4 1494888 Plug (Yellow) .............................................................................................. 2 2
5 1599415 Plug (Yellow) .............................................................................................. 1 1
6 4010332 Bumper (RH) .............................................................................................. 1 1
7 1382472
1502543 Nut .............................................................................................................. 2 2
8 4010331 Bumper (LH) ............................................................................................... 1 1
9 1527888 Capscrew ................................................................................................... 4 4
10 4041480 Hinge (Attaches to Overhead Guard) ........................................................ 2 2
11 1370949
1528888 Nut (Shoulder) ............................................................................................ 4 4
12 1683193 Bolt ............................................................................................................. 2 2
13 302402 Locknut ....................................................................................................... 2 2
14 1581558 Washer ....................................................................................................... 2 2
15 4020998 Ball Stud ..................................................................................................... 4 4
16 1677115 Clip ............................................................................................................. 4 4
17 b 4002221 Gas Spring ................................................................................................. 2 2
17 a 4047372 Gas Spring ................................................................................................. 2 2
18 292655 Nut .............................................................................................................. 3 3
KEY:
A: UL-E
B: UL-EE
QTY
ITEM PART NO. DESCRIPTION A B
19 4001872 Hood Latch ................................................................................................. 1 ..
19 4027592 Latch Assembly .......................................................................................... .. 1
20 2028137 Capscrew ................................................................................................... 3 ..
20 1384659 Capscrew ................................................................................................... .. 3
21 320159 Washer ....................................................................................................... 6 6
22 4054998 Bearing ....................................................................................................... 4 4
FOOTNOTES:
a With Full Suspension Seat b With Non-Suspension Seat
KEY:
A: UL-E
B: UL-EE
QTY
ITEM PART NO. DESCRIPTION A B
1 4023074 Hood ........................................................................................................... 1 1
2 4023670 Cover .......................................................................................................... 1 1
3 1494888 Plug (Yellow) .............................................................................................. 2 2
4 4041522 Pin .............................................................................................................. 2 2
5 4045266 Spacer ........................................................................................................ 4 4
6 4041486 Plate Wldmt ................................................................................................ 2 2
7 18832 Cotter Pin ................................................................................................... 2 2
8 302402 Locknut ....................................................................................................... 2 2
9 1683193 Bolt ............................................................................................................. 2 2
10 296042 Capscrew ................................................................................................... 4 4
11 320161 Washer ....................................................................................................... 4 4
12 300937 Nut .............................................................................................................. 4 4
13 e 4042631 Bumper ....................................................................................................... 1 1
14 1512403 Capscrew ................................................................................................... 2 2
15 1516800 Shim (0.060 in.) .......................................................................................... AR AR
16 316826 Nut .............................................................................................................. 2 2
17 4042887 Plate Wldmt (Attaches to Overhead Guard) ............................................... 1 1
18 248212 Snap Ring .................................................................................................. 2 2
19 4047463 Wear Sleeve ............................................................................................... 2 2
20 d 4023527 Spring (LH) ................................................................................................. 1 1
20 d 4023560 Spring (RH) ................................................................................................ 1 1
KEY:
A: UL-E
B: UL-EE
QTY
ITEM PART NO. DESCRIPTION A B
20 c 4023527 Spring (For Heavy Duty Option) ................................................................. 2 2
21 304523 Snap Ring .................................................................................................. 4 4
22 4047556 Bar .............................................................................................................. 2 2
23 4023351 Spacer ........................................................................................................ 1 1
24 1527876 Capscrew ................................................................................................... 2 2
25 4041040 Plate ........................................................................................................... 1 1
26 4041038 Link ............................................................................................................. 1 1
27 1661274 Bolt ............................................................................................................. 1 1
28 139 Pin .............................................................................................................. 1 1
29 18828 Cotter Pin ................................................................................................... 1 1
30 1661162 Handle (Hood) ............................................................................................ 3 3
31 2027940 Plug ............................................................................................................ 4 4
32 1494888 Plug (Yellow) .............................................................................................. 2 2
33 1599415 Plug (Yellow) .............................................................................................. 1 1
34 4001872 Hood Latch ................................................................................................. 1 ..
34 4027592 Latch Assembly .......................................................................................... .. 1
35 292655 Nut .............................................................................................................. 3 3
36 2028137 Capscrew ................................................................................................... 3 ..
36 1384659 Capscrew ................................................................................................... .. 3
37 320159 Washer ....................................................................................................... 6 6
a b 4616925 Label (Torsion Spring Warning) ................................................................. 1 1
FOOTNOTES:
a Apply to Item 17 d With Non-Suspension Seat
b Not Illustrated e → 12/2012
c With Full Suspension Seat
KEY:
A: UL-E
B: UL-EE
QTY
ITEM PART NO. DESCRIPTION A B
1 4023073 Hood ........................................................................................................... 1 ..
1 4000458 Hood ........................................................................................................... .. 1
2 4023066 Cover .......................................................................................................... 1 ..
2 4023065 Cover .......................................................................................................... .. 1
3 1494888 Plug (Yellow) .............................................................................................. 2 2
4 4041522 Pin .............................................................................................................. 2 2
5 4045266 Spacer ........................................................................................................ 4 4
6 4041485 Plate Wldmt ................................................................................................ 2 2
7 18832 Cotter Pin ................................................................................................... 2 2
8 302402 Locknut ....................................................................................................... 2 2
9 1683193 Bolt ............................................................................................................. 2 2
10 296042 Capscrew ................................................................................................... 4 4
11 320161 Washer ....................................................................................................... 4 4
12 300937 Nut .............................................................................................................. 4 4
13 e 4042631 Bumper ....................................................................................................... 1 1
14 1512403 Capscrew ................................................................................................... 2 2
15 1516800 Shim (0.060 in.) .......................................................................................... AR AR
16 316826 Nut .............................................................................................................. 2 2
17 4042887 Plate Wldmt (Attaches to Overhead Guard) ............................................... 1 1
18 248212 Snap Ring .................................................................................................. 2 2
19 4047463 Wear Sleeve ............................................................................................... 2 2
KEY:
A: UL-E
B: UL-EE
QTY
ITEM PART NO. DESCRIPTION A B
20 d 4023527 Spring (LH) ................................................................................................. 1 1
20 d 4023560 Spring (RH) ................................................................................................ 1 1
20 c 4023527 Spring (Heavy Duty Option) ....................................................................... 2 2
21 304523 Snap Ring .................................................................................................. 2 2
22 4047556 Bar .............................................................................................................. 2 2
23 4023351 Spacer ........................................................................................................ 1 1
24 1527876 Capscrew ................................................................................................... 2 2
25 4041040 Plate ........................................................................................................... 1 1
26 4041884 Link ............................................................................................................. 1 1
27 1661274 Bolt ............................................................................................................. 1 1
28 139 Pin .............................................................................................................. 1 1
29 18828 Cotter Pin ................................................................................................... 1 1
30 1661162 Handle (Hood) ............................................................................................ 3 3
31 2027940 Plug ............................................................................................................ 4 4
32 1494888 Plug (Yellow) .............................................................................................. 2 2
33 1599415 Plug (Yellow) .............................................................................................. 1 1
34 4001872 Hood Latch ................................................................................................. 1 ..
34 4027592 Latch Assembly .......................................................................................... .. 1
35 292655 Nut .............................................................................................................. 3 3
36 2028137 Capscrew ................................................................................................... 3 ..
36 1384659 Capscrew ................................................................................................... .. 3
37 320159 Washer ....................................................................................................... .. 6
a b 4616925 Label (Torsion Spring Warning) ................................................................. 1 1
FOOTNOTES:
a Apply to Item 17 d With Non-Suspension Seat
b Not Illustrated e → 12/2012
c With Full Suspension Seat
KEY:
A: UL-E
B: UL-EE
QTY
ITEM PART NO. DESCRIPTION A B
1 4023073 Hood ........................................................................................................... 1 ..
1 4000458 Hood ........................................................................................................... .. 1
2 4023669 Cover .......................................................................................................... 1 ..
2 4023067 Cover .......................................................................................................... .. 1
3 1494888 Plug (Yellow) .............................................................................................. 2 2
4 4041522 Pin .............................................................................................................. 2 2
5 4045266 Spacer ........................................................................................................ 4 4
6 4041487 Plate Wldmt ................................................................................................ 2 2
7 18832 Cotter Pin ................................................................................................... 2 2
8 302402 Locknut ....................................................................................................... 2 2
9 1683193 Bolt ............................................................................................................. 2 2
10 296042 Capscrew ................................................................................................... 4 4
11 320161 Washer ....................................................................................................... 4 4
12 300937 Nut .............................................................................................................. 4 4
13 e 4042631 Bumper ....................................................................................................... 1 1
14 1512403 Capscrew ................................................................................................... 2 2
15 1516800 Shim (0.060 in.) .......................................................................................... AR AR
16 316826 Nut .............................................................................................................. 2 2
17 4042887 Plate Wldmt (Attaches to Overhead Guard) ............................................... 1 1
18 248212 Snap Ring .................................................................................................. 2 2
19 4047463 Wear Sleeve ............................................................................................... 2 2
KEY:
A: UL-E
B: UL-EE
QTY
ITEM PART NO. DESCRIPTION A B
20 d 4023527 Spring (LH) ................................................................................................. 1 1
20 d 4023560 Spring (RH) ................................................................................................ 1 1
20 c 4023527 Spring (Heavy Duty Option) ....................................................................... 2 2
21 304523 Snap Ring .................................................................................................. 2 2
22 4047556 Bar .............................................................................................................. 2 2
23 4023351 Spacer ........................................................................................................ 1 1
24 1527876 Capscrew ................................................................................................... 2 2
25 4041040 Plate ........................................................................................................... 1 1
26 4037157 Link ............................................................................................................. 1 1
27 1661274 Bolt ............................................................................................................. 1 1
28 139 Pin .............................................................................................................. 1 1
29 18828 Cotter Pin ................................................................................................... 1 1
30 1661162 Handle (Hood) ............................................................................................ 3 3
31 2027940 Plug ............................................................................................................ 4 4
32 1494888 Plug (Yellow) .............................................................................................. 2 2
33 1599415 Plug (Yellow) .............................................................................................. 1 1
34 4001872 Hood Latch ................................................................................................. 1 ..
34 4027592 Latch Assembly .......................................................................................... .. 1
35 292655 Nut .............................................................................................................. 3 3
36 2028137 Capscrew ................................................................................................... 3 ..
36 1384659 Capscrew ................................................................................................... .. 3
37 320159 Washer ....................................................................................................... .. 6
38 1585581 Bumper (Hood) ........................................................................................... 1 1
39 313828 Nut .............................................................................................................. 1 1
a b 4616925 Label (Torsion Spring Warning) ................................................................. 1 1
FOOTNOTES:
a Apply to Item 17 d With Non-Suspension Seat
b Not Illustrated e → 12/2012
c With Full Suspension Seat
SEATS
NON SUSPENSION – WITH HIP RESTRAINTS
KEY:
A: With Vinyl Seat
B: With Cloth Seat
QTY
ITEM PART NO. DESCRIPTION A B
4615812
4636318 Seat-Non Suspension Assy (Vinyl) ............................................................ 1 ..
4607331 Seat-Non Suspension (Cloth) .................................................................... .. 1
1 4238027 Seat-Non Suspension (Base) ................................................................ 1 ..
1 1584113 Seat -Non Suspension (Base) ............................................................... .. 1
1 4238027 Seat-Non Suspension (Base) ................................................................ 1 ..
2 296463 Screw ..................................................................................................... 4 4
3 4030278 Box , Operator Manual (Operator Manual Storage) ............................... 1 ..
3 1584060 Box (Book) (Operator Manual Storage) ................................................. .. 1
4 4030279 Cover (Manual Storage Box) ................................................................. 1 ..
4 1482950 Cover (Manual Storage Box) ................................................................. .. 1
5 ..... Hip Restraint (LH) .................................................................................. 1 ..
5 1563216 Hip Restraint (LH) .................................................................................. .. 1
6 4618438 Seat Rail Assembly (Includes Locking and Slave Seat Rails) ............... 1 ..
6 1690996 Kit-Seat Rail ........................................................................................... .. 1
7 136749 Screw ..................................................................................................... 10 10
8 4615811 Sensor Assy (Operator Presence) ......................................................... 1 ..
8 1709876 Sensor (Operator Presence) .................................................................. .. 1
9 4615969 Sensor (Operator Presence System) ..................................................... 1 ..
9 4013095 Wire Harness (Operator Presence System) .......................................... .. 1
10 1479453 Clamp .................................................................................................... 1 ..
10 ..... Clamp .................................................................................................... .. 1
11 ..... Hip Restraint (RH) ................................................................................. 1 ..
11 1563217 Hip Restraint (RH) ................................................................................. .. 1
12 1641250 Seat Belt , High Visibility, Red .................................................................... 1 1
12 1598504 Kit-Seat Belt (Black) ................................................................................... 1 1
12 4053079 Seat Belt (High Visibility with Interlock) ...................................................... 1 1
13 221353 Locknut ....................................................................................................... 2 2
14 19901 Roll Pin ....................................................................................................... 1 1
15 15177 Washer ....................................................................................................... 3 3
16 16375 Capscrew ................................................................................................... 2 2
17 b 4004912 Plate ........................................................................................................... 2 2
17 c 4128063 Plate ........................................................................................................... 2 2
18 1608654 Capscrew ................................................................................................... 4 4
19 1593334 Nut .............................................................................................................. 2 2
20 1705438 Bracket ....................................................................................................... 1 1
21 272133 Clamp ......................................................................................................... 1 1
22 15127 Washer ....................................................................................................... 1 1
23 292500 Capscrew ................................................................................................... 2 2
a 1581852 Washer (Seat Belt) ..................................................................................... 3 3
a 2107969 Cover (Seat-Side Electrical) (FFigure 2-1)................................................ 1 1
FOOTNOTES:
a Not Illustrated c S/N A099N03681S →
b → S/N A099N03680S
NOTES
SEATS
NON SUSPENSION – LOW PROFILE WITH HIP RESTRAINTS
KEY:
A: With Vinyl Seat
B: With Cloth Seat
QTY
ITEM PART NO. DESCRIPTION A B
4607055 Seat Assy (Vinyl) ........................................................................................ 1 ..
4606920 Seat Assy (Cloth) ....................................................................................... .. 1
1 4031930 Cushion (Vinyl) ...................................................................................... 1 ..
1 4031933 Cushion (Cloth) ...................................................................................... .. 1
2 ..... Screw ..................................................................................................... .. ..
3 1584060 Box (Book) (Operator Manual Storage) ................................................. 1 1
4 1482950 Cover (Manual Storage Box) ................................................................. 1 1
5 1563216 Hip Restraint (LH) .................................................................................. 1 1
6 1690996 Kit-Seat Rail ........................................................................................... 1 1
7 ..... Screw ..................................................................................................... .. ..
8 1563215 Sensor (Operator Presence) .................................................................. 1 1
9 1692919 Wire Harness (Operator Presence System) .......................................... 1 1
10 ..... Clamp .................................................................................................... .. ..
11 1563217 Hip Restraint (RH) ................................................................................. 1 1
12 1641250 Seat Belt , High Visibility, Red .................................................................... 1 1
12 1598504 Kit-Seat Belt (Black) ................................................................................... 1 1
12 4053079 Seat Belt (High Visibility with Interlock) ...................................................... 1 1
13 221353 Locknut ....................................................................................................... 2 2
14 19901 Roll Pin ....................................................................................................... 1 1
15 15177 Washer ....................................................................................................... 3 3
16 16375 Capscrew ................................................................................................... 2 2
17 1705438 Bracket ....................................................................................................... 1 1
18 1613324 Capscrew ................................................................................................... 4 4
19 15000 Nut .............................................................................................................. 2 2
20 16378 Capscrew ................................................................................................... 2 2
21 1479453 Clamp ......................................................................................................... 1 1
22 296379 Washer ....................................................................................................... 2 2
a 1581852 Washer (Seat Belt) ..................................................................................... 3 3
a 2107969 Cover (Seat-Side Electrical) (FFigure 2-1)................................................ 1 1
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Also Includes Tether and 1703891 Kit-Recliner on c With Restricted Suspension
Sheet 2
b Not Illustrated
FOOTNOTES:
a Included with Seat b Included with Seat and Non Swivel/Swivel Sets
FOOTNOTES:
a Not Illustrated c S/N A099N03681S →
b → S/N A099N03680S
NOTES
NOTES
KEY:
A: Class III 125 x 50 (5" x 2")
B: Class III 150 x 50 (6" x 2")
C: Class IV 150 x 50 (6" x 2")
D: Class IV 150 x 60 (6" x 2.4)
QTY
ITEM PART NO. DESCRIPTION A B C D
1 367419 Fork (36 in.) .............................................................................. 2 .. .. ..
1 367420 Fork (42 in.) .............................................................................. 2 .. .. ..
1 367421 Fork (48 in.) .............................................................................. 2 .. .. ..
1 367422 Fork (54 in.) .............................................................................. 2 .. .. ..
1 367423 Fork (60 in.) .............................................................................. 2 .. .. ..
1 367424 Fork (72 in.) .............................................................................. 2 .. .. ..
1 1399912 Fork (36 in.) .............................................................................. .. 2 .. ..
1 1399913 Fork (42 in.) .............................................................................. .. 2 .. ..
1 1399914 Fork (48 in.) .............................................................................. .. 2 .. ..
1 1399915 Fork (54 in.) .............................................................................. .. 2 .. ..
1 1399916 Fork (60 in.) .............................................................................. .. 2 .. ..
1 1399917 Fork (72 in.) .............................................................................. .. 2 .. ..
1 1399918 Fork (36 in.) .............................................................................. .. .. 2 ..
1 1399919 Fork (42 in.) .............................................................................. .. .. 2 ..
1 1399920 Fork (48 in.) .............................................................................. .. .. 2 ..
1 1399921 Fork (54 in.) .............................................................................. .. .. 2 ..
1 1399922 Fork (60 in.) .............................................................................. .. .. 2 ..
1 1399923 Fork (72 in.) .............................................................................. .. .. 2 ..
1 1458263 Fork (36 in.) .............................................................................. .. .. .. 2
1 1458264 Fork (42 in.) .............................................................................. .. .. .. 2
1 1333001 Fork (48 in.) .............................................................................. .. .. .. 2
KEY:
A: Class III 125 x 50 (5" x 2")
B: Class III 150 x 50 (6" x 2")
C: Class IV 150 x 50 (6" x 2")
D: Class IV 150 x 60 (6" x 2.4)
QTY
ITEM PART NO. DESCRIPTION A B C D
1 1333002 Fork (54 in.) .............................................................................. .. .. .. 2
1 1333003 Fork (60 in.) .............................................................................. .. .. .. 2
1 1333004 Fork (72 in.) .............................................................................. .. .. .. 2
2 1523734 Pin , Pin Retainer ...................................................................... 1 1 1 1
3 1523732 Knob ......................................................................................... 1 1 1 1
4 1500784 Spring ....................................................................................... 1 1 .. ..
4 1500786 Spring ....................................................................................... .. .. 1 1
5 1523737 Pin ............................................................................................. 1 1 .. ..
5 1523741 Pin ............................................................................................. .. .. 1 1
1523739 Kit-Latch (Class III) ................................................................... 2 2 .. ..
1523742 Kit-Latch (Class IV) ................................................................... .. .. 2 2
KEY:
A: Class III 200 x 40 (7.8 in x 1.6 in)
B: Class IV 250 x 40 (9.8 in x 1.6 in)
QTY
ITEM PART NO. DESCRIPTION A B
1 1465545 Fork (47.5 in.) ............................................................................................. 2 ..
1 1465546 Fork (54 in.) ................................................................................................ 2 ..
1 1465547 Fork (47.5 in.) ............................................................................................. .. 2
1 1465548 Fork (54 in.) ................................................................................................ .. 2
2 1523734 Pin , Pin Retainer ....................................................................................... 1 1
3 1523732 Knob ........................................................................................................... 1 1
4 1500784 Spring ......................................................................................................... 1 ..
4 1500786 Spring ......................................................................................................... .. 1
5 1523737 Pin .............................................................................................................. 1 ..
5 1523741 Pin .............................................................................................................. .. 1
1523739 Kit-Latch (Class III) ..................................................................................... 2 ..
1523742 Kit-Latch (Class IV) .................................................................................... .. 1
KEY:
A: Class III 125 x 50 (4.9 in x 1.9 in)
B: Class III 150 x 50 (7.8 in x 1.9 in)
C: Class IV 250 x 40 (9.8 in x 1.6 in)
QTY
ITEM PART NO. DESCRIPTION A B C
1 b 1378732 Fork (36 in.) ....................................................................................... 2 .. ..
1 b 1378733 Fork (42 in.) ....................................................................................... 2 .. ..
1 b 1378734 Fork (48 in.) ....................................................................................... 2 .. ..
1 b 1378735 Fork (54 in.) ....................................................................................... 2 .. ..
1 b 1378736 Fork (60 in.) ....................................................................................... 2 .. ..
1 b 1378737 Fork (72 in.) ....................................................................................... 2 .. ..
1 a 1465658 Fork (47.5 in.) .................................................................................... .. 2 ..
1 a 1465659 Fork (54 in.) ....................................................................................... .. 2 ..
1 a 1465660 Fork (47.5 in.) .................................................................................... .. .. 2
1 a 1465661 Fork (54 in.) ....................................................................................... .. .. 2
2 302450 Roll Pin .............................................................................................. 1 1 1
3 1378763 Latch .................................................................................................. 1 1 1
4 1378762 Spring ................................................................................................ 1 1 1
5 1378761 Fork (Pin) ........................................................................................... 1 1 1
1378766 Kit-Latch (Class III And IV) ................................................................ 2 2 2
FOOTNOTES:
a Polished Fork and Full Bottom Taper b Standard Taper
KEY:
A: Class III 125 x 50 (4.9 in x 1.9 in.) Standard Taper
B: Class IV 150 x 60 (7.8 in. x 2.4 in) Standard Taper
C: Class III 150 x 50 (7.8 in x 1.9 in) Standard Taper
D: Class IV 150 x 50 (7.8 in x 1.9 in) Standard Taper
QTY
ITEM PART NO. DESCRIPTION A B C D
1 4083870 Fork (36 in.) .............................................................................. 2 .. .. ..
1 4083874 Fork (42 in.) .............................................................................. 2 .. .. ..
1 4083876 Fork (48 in.) .............................................................................. 2 .. .. ..
1 4083878 Fork (54 in) ............................................................................... 2 .. .. ..
1 4083881 Fork (60 in.) .............................................................................. 2 .. .. ..
1 4083883 Fork (72 in.) .............................................................................. 2 .. .. ..
1 4084056 Fork (36in) ................................................................................ .. 2 .. ..
1 4084059 Fork (42in) ................................................................................ .. 2 .. ..
1 4084062 Fork (48 in.) .............................................................................. .. 2 .. ..
1 4084064 Fork (54 in.) .............................................................................. .. 2 .. ..
1 4084067 Fork (60 in.) .............................................................................. .. 2 .. ..
1 4084070 Fork (72 in) ............................................................................... .. 2 .. ..
1 4084025 Fork (36in) ................................................................................ .. .. 2 ..
1 4084027 Fork (42in.) ............................................................................... .. .. 2 ..
1 4084028 Fork (48 in.) .............................................................................. .. .. 2 ..
1 4084029 Fork (54 in.) .............................................................................. .. .. 2 ..
1 4084030 Fork (60in.) ............................................................................... .. .. 2 ..
1 4084031 Fork (72 in) ............................................................................... .. .. 2 ..
1 4084039 Fork (36in) ................................................................................ .. .. .. 2
1 4084040 Fork (42in) ................................................................................ .. .. .. 2
1 4084041 Fork (48in.) ............................................................................... .. .. .. 2
1 4084042 Fork (54 in.) .............................................................................. .. .. .. 2
KEY:
A: Class III 125 x 50 (4.9 in x 1.9 in.) Standard Taper
B: Class IV 150 x 60 (7.8 in. x 2.4 in) Standard Taper
C: Class III 150 x 50 (7.8 in x 1.9 in) Standard Taper
D: Class IV 150 x 50 (7.8 in x 1.9 in) Standard Taper
QTY
ITEM PART NO. DESCRIPTION A B C D
1 4084043 Fork (60in.) ............................................................................... .. .. .. 2
1 4084044 Fork (72in) ................................................................................ .. .. .. 2
2 ..... Pin ........................................................................................ 1 1 1 1
3 ..... Lever ..................................................................................... 1 1 1 1
4 ..... Spring ................................................................................... 1 .. 1 ..
4 ..... Spring ................................................................................... .. 1 .. 1
5 ..... Pin ........................................................................................ 1 .. 1 ..
5 ..... Pin ............................................................................................. .. 1 .. 1
4083889 Kit Fork Latch Mechanism ........................................................ 2 .. 2 ..
4083890 Kit Fork Latch Mechanism (Class 4A) ...................................... .. 2 .. 2
KEY:
A: Class III 200 x 40 (7.8in. x 1.6 in)
B: Class IV 250 x 40 (9.8 in x1.6 in)
QTY
ITEM PART NO. DESCRIPTION A B
1 4083728 Fork (47.5 in) .............................................................................................. 2 ..
1 4083729 Fork (54 in) ................................................................................................. 2 ..
1 4083730 Fork (47.5 in) .............................................................................................. .. 2
1 4083731 Fork (54in) .................................................................................................. .. 2
2 ..... Pin .......................................................................................................... 1 1
3 ..... Lever ...................................................................................................... 1 1
4 ..... Spring .................................................................................................... 1 ..
4 ..... Spring .................................................................................................... .. 1
5 ..... Pin .......................................................................................................... 1 ..
5 ..... Pin .............................................................................................................. .. 1
4083889 Kit Fork Latch Mechanism .......................................................................... 2 ..
4083890 Kit Fork Latch Mechanism (Class 4A) ........................................................ .. 1
NOTES
FOOTNOTES:
a Optional
FOOTNOTES:
a Contact your Local Hyster Dealer c Use to Attach Item 7 to Hydraulic Breather
b Not Illustrated
FOOTNOTES:
a Contact Your Local Hyster Dealer
NOTES
2 ELECTRICAL SYSTEM
UNIT CODE A099
11/2018 NORTH AMERICA
SECTION 2
ELECTRICAL SYSTEM
DESCRIPTION PAGE
BATTERY CONNECTOR
RAPID CHARGE OPTION .......................................................................................................................... 2-22
WITH FLAT OVERHEAD GUARD - LWB (E100-120XN) (→ 11/2014) ..................................................... 2-13
WITH FLAT OVERHEAD GUARD - LWB (E100-120XN) (11/2014 →) ..................................................... 2-16
WITH FLAT OVERHEAD GUARD - SWB (E80-100XNS) (→ 11/2014) .................................................... 2-18
WITH FLAT OVERHEAD GUARD - SWB (E80-100XNS) (11/2014 →) .................................................... 2-20
WITH STANDARD OVERHEAD GUARD - LWB (E100-120XN) (→ 11/2014) .......................................... 2-7
WITH STANDARD OVERHEAD GUARD - LWB (E100-120XN) (11/2014 →) .......................................... 2-10
WITH STANDARD OVERHEAD GUARD - SWB (E80-100XNS) ............................................................... 2-12
CONTACTOR AND FUSE ASSEMBLY
→ 11/2015 .................................................................................................................................................. 2-24
SEALED (11/2015 →) ................................................................................................................................ 2-26
CONTACTOR ASSEMBLY
UL-E ............................................................................................................................................................ 2-28
UL-EE .......................................................................................................................................................... 2-30
CONTROL PANELS AND CONTACTORS ..................................................................................................... 2-23
CONTROLLER ASSEMBLY
PUMP AND TRACTION (11/2014 →) ........................................................................................................ 2-36
PUMP MOTOR (→ 11/2014) ...................................................................................................................... 2-32
TRACTION MOTOR (→ 11/2014) .............................................................................................................. 2-34
DISPLAY
LOW MOUNT .............................................................................................................................................. 2-48
DISPLAY GROUP AND HARNESS
HIGH MOUNT ............................................................................................................................................. 2-46
ELECTRICAL ARRANGEMENT ..................................................................................................................... 2-4
LIGHTS ............................................................................................................................................................ 2-50
MINI-LEVER CONTROLS
3 FUNCTION ............................................................................................................................................... 2-54
4 FUNCTION ............................................................................................................................................... 2-58
POWER CABLES
E100-120XN (→ 11/2014) .......................................................................................................................... 2-42
E100-120XN (11/2014 →) .......................................................................................................................... 2-44
E80-100XNS (→ 11/2014) ......................................................................................................................... 2-38
E80-100XNS (11/2014 →) ......................................................................................................................... 2-40
TILT SENSOR GROUP ................................................................................................................................... 2-61
TRACTION SPEED LIMITER
STANDARD AND INTEGRAL SIDE-SHIFT CARRIAGES .......................................................................... 2-62
VEHICLE SYSTEM MANAGER ...................................................................................................................... 2-64
WIRE HARNESS
EMERGENCY DISCONNECT .................................................................................................................... 2-72
FRONT SWITCH ......................................................................................................................................... 2-73
JUMPER, REAR GRAB HANDLE ............................................................................................................... 2-169
LEFT HAND - WITHOUT TURN SIGNALS (10/2013 →) ........................................................................... 2-76
LIGHTS - LEFT HAND (→ 10/2013) .......................................................................................................... 2-74
MAIN - MANUAL HYDRAULIC SHEET 1 OF 3 (→ 11/2014) .................................................................... 2-78
MAIN - MANUAL HYDRAULIC SHEET 2 OF 3 (→ 11/2014) .................................................................... 2-82
MAIN - MANUAL HYDRAULIC SHEET 3 OF 3 (→ 11/2014) .................................................................... 2-86
MAIN - MANUAL HYDRAULIC SHEET 1 OF 3 (11/2014 ↔ 11/2015) ...................................................... 2-90
MAIN - MANUAL HYDRAULIC SHEET 2 OF 3 (11/2014 ↔ 11/2015) ...................................................... 2-94
©2018 HYSTER COMPANY See Service Manual 2-1
for service procedures.
UNIT CODE A099
NORTH AMERICA 11/2018
SECTION 2
ELECTRICAL SYSTEM
DESCRIPTION PAGE
NOTES
ELECTRICAL ARRANGEMENT
KEY:
A: With Manual Hydraulics
B: With Electro-Hydraulics
QTY
ITEM PART NO. DESCRIPTION A B
1 c 4610566 Wire Harness (Main) (FFigure 2-40, FFigure 2-41, FFigure 2-42)......... 1 ..
1 d 4634423 Wire Harness (Main) (FFigure 2-43, FFigure 2-44, FFigure 2-45)......... 1 ..
1 e 4641506 Wire Harness (Main) (FFigure 2-46, FFigure 2-47, FFigure 2-48)......... 1 ..
1 c 4610568 Wire Harness (Main) (FFigure 2-49, FFigure 2-50, FFigure 2-51)......... .. 1
1 d 4634359 Wire Harness (Main) (FFigure 2-52, FFigure 2-53, FFigure 2-54)......... .. 1
1 e 4641507 Wire Harness (Main) (FFigure 2-55, FFigure 2-56, FFigure 2-57)......... .. 1
2 2104097 Wire Harness (Seat) (FFigure 2-62)......................................................... 1 ..
2 2104030 Wire Harness (Seat) (FFigure 2-64)......................................................... .. 1
2 b 4635373 Wire Harness (Seat) (FFigure 2-63)......................................................... 1 ..
2 b 4635372 Wire Harness (Seat) (FFigure 2-65)......................................................... .. 1
3 1402815 Clip ............................................................................................................. 1 1
4 2107319 Grommet (Attaches to Hood) ..................................................................... 1 1
5 129563 Strap Clamp ............................................................................................... 1 1
6 1694830 Capscrew ................................................................................................... 2 2
7 296357 Washer ....................................................................................................... 2 2
8 2107969 Cover (Seat-Side Electrical) ....................................................................... 1 1
9 2108591 Wire Harness (Steer Column) (FFigure 2-66)........................................... 1 1
10 4610580 Wire Harness (Synchronous Steering) (FFigure 2-67)............................. 1 1
11 1382472
1502543 Nut .............................................................................................................. 1 1
12 2105928 Horn (48 V) ................................................................................................. 1 1
12 2102796
2105929 Horn (80 V) ................................................................................................. 1 1
13 1510113 Capscrew ................................................................................................... 1 1
14 4611043 Bracket ....................................................................................................... 1 1
15 4019192 Clip , Nut .................................................................................................... 2 2
16 296153 Capscrew ................................................................................................... 2 2
17 2100367 Relay (Mini) ................................................................................................ 1 ..
18 4609161 Relay (Mini Power) ..................................................................................... .. 1
19 ..... Vehicle System Manager (FFigure 2-29).................................................. 1 1
20 4616858 Wire Harness (Main Lights Chassis) (48 V) (FFigure 2-58)...................... 1 1
20 4610567 Wire Harness (Main Lights Chassis) (80 V) (FFigure 2-58)...................... 1 1
20 4610584 Wire Harness (Without Lights) (FFigure 2-60).......................................... 1 1
21 ..... DC-DC Converter ....................................................................................... 1 1
22 ..... Impact Sensor (FFigure 10-9)................................................................... 1 1
23 1509890 Clip ............................................................................................................. 1 1
24 b 4634955
4651927
4655560 Control Module (Seat Belt Sequence) ....................................................... 1 1
24 b 4634955
4651927
4655560 Control Module (Seat Belt Sequence) (Alternate Part) .............................. 1 1
24 4103377 Tape ........................................................................................................... 1 1
a 1463849 Lubricant .................................................................................................... AR AR
FOOTNOTES:
a Not Illustrated d 11/2014 ↔ 11/2015
b With Seat Belt Sequence Module e 11/2015 →
c → 11/2014
KEY:
A: 36 Volt
B: 48 Volt
C: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B C
1 4624444 Battery Connector (Assembly) (SB) .................................................. 1 .. ..
1 2065711 Battery Connector ......................................................................... 1 .. ..
1 4028319 Conduit .......................................................................................... AR .. ..
1 4624447 Battery Connector (Assembly) (SB) .................................................. .. 1 ..
1 2097782 Battery Connector ......................................................................... .. 1 ..
1 4028319 Conduit .......................................................................................... .. AR ..
1 4624445 Battery Connector (Assembly) (SBE) ................................................ 1 .. ..
1 4035983 Battery Connector ......................................................................... 1 .. ..
1 4028319 Conduit .......................................................................................... AR .. ..
1 4624446 Battery Connector (Assembly) (SBE) ................................................ .. 1 ..
1 4035984 Battery Connector ......................................................................... .. 1 ..
1 4028319 Conduit .......................................................................................... .. AR ..
1 4624441 Battery Connector (SBE) ................................................................... .. .. 1
1 4035985 Battery Connector ......................................................................... .. .. 1
1 4028319 Conduit .......................................................................................... .. .. AR
1 4629801 Battery Connector (Assembly) (DIN) ................................................. 1 1 ..
1 4018696 Battery Connector ......................................................................... 1 1 ..
2 2062875 Capscrew .......................................................................................... 2 2 2
2 292507 Capscrew (Alternate) ......................................................................... 1 1 ..
3 1531558 Insert ................................................................................................. 2 2 2
KEY:
A: 36 Volt
B: 48 Volt
C: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B C
4 1581836 Capscrew .......................................................................................... 2 2 2
5 4609349 Hose Clamp ....................................................................................... 2 2 2
6 4027909 Clamp ................................................................................................ 2 2 2
7 1531557 Insert ................................................................................................. 1 1 1
8 1677721 Insert ................................................................................................. 1 1 1
9 ..... Contactors (FFigure 2-11)................................................................ .. .. ..
10 ..... Control Panels (FFigure 2-10).......................................................... .. .. ..
NOTES
BATTERY CONNECTOR
WITH STANDARD OVERHEAD GUARD – LWB (E100-120XN) (11/2014 →)
KEY:
A: 36 Volt
B: 48 Volt
C: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B C
1 4098243 Battery Connector (SB) ..................................................................... 1 .. ..
1 4098246 Battery Connector (SB) ..................................................................... .. 1 ..
1 4098248 Battery Connector (SBE) ................................................................... 1 .. ..
1 4035983 Battery Connector ......................................................................... 1 .. ..
1 4098250 Battery Connector (SBE) ................................................................... .. 1 ..
1 4035984 Battery Connector ......................................................................... .. 1 ..
1 4098252 Battery Connector (SBE) ................................................................... .. .. 1
1 4035985 Battery Connector ......................................................................... .. .. 1
2 2062875 Capscrew .......................................................................................... 2 2 2
3 1531558 Insert ................................................................................................. 2 2 2
4 1581836 Capscrew .......................................................................................... 2 2 2
5 4609349 Hose Clamp ....................................................................................... 2 2 2
6 4027909 Clamp ................................................................................................ 2 2 2
7 1531557 Insert ................................................................................................. 1 1 1
8 1677721 Insert ................................................................................................. 1 1 1
9 ..... Contactors (FFigure 2-11)................................................................ .. .. ..
10 ..... Control Panels (FFigure 2-17).......................................................... .. .. ..
KEY:
A: 36 Volt
B: 48 Volt
C: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B C
1 2062875 Capscrew .......................................................................................... 2 2 2
2 4611588 Battery Connector (Assembly) (SB) .................................................. 1 .. ..
2 2065711 Battery Connector ......................................................................... 1 .. ..
2 4028319 Conduit .......................................................................................... AR .. ..
2 4611589 Battery Connector (SBE) ................................................................... 1 .. ..
2 4035983 Battery Connector ......................................................................... 1 .. ..
2 4028319 Conduit .......................................................................................... AR .. ..
2 4611586 Battery Connector (SB) ..................................................................... .. 1 ..
2 2097782 Battery Connector ......................................................................... .. 1 ..
2 4028319 Conduit .......................................................................................... .. AR ..
2 4611590 Battery Connector (SBE) ................................................................... .. 1 ..
2 4035984 Battery Connector ......................................................................... .. 1 ..
2 4028319 Conduit .......................................................................................... .. AR ..
2 4611587 Battery Connector (SBE) ................................................................... .. .. 1
2 4035985 Battery Connector ......................................................................... .. .. 1
2 4028319 Conduit .......................................................................................... .. .. AR
2 4629919 Battery Connector (Assembly) (DIN) ................................................. 1 1 ..
3 1531558 Insert ................................................................................................. 2 2 2
4 ..... Contactors (FFigure 2-11)................................................................ .. .. ..
5 ..... Control Panels (FFigure 2-10, FFigure 2-17).................................. .. .. ..
KEY:
A: 36 Volt
B: 48 Volt
C: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B C
1 4624450 Battery Connector (Assembly) (SB) .................................................. 1 .. ..
1 2065711 Battery Connector ......................................................................... 1 .. ..
1 4028319 Conduit .......................................................................................... AR .. ..
1 4624451 Battery Connector (Assembly) (SB) .................................................. .. 1 ..
1 2097782 Battery Connector ......................................................................... .. 1 ..
1 4028319 Conduit .......................................................................................... .. AR ..
1 4624448 Battery Connector (Assembly) (SBE) ................................................ 1 .. ..
1 4035983 Battery Connector ......................................................................... 1 .. ..
1 4028319 Conduit .......................................................................................... AR .. ..
1 4624449 Battery Connector (Assembly) (SBE) ................................................ .. 1 ..
1 4035984 Battery Connector ......................................................................... .. 1 ..
1 4028319 Conduit .......................................................................................... .. AR ..
1 4624442 Battery Connector (Assembly) (SBE) ................................................ .. .. 1
1 4035985 Battery Connector ......................................................................... .. .. 1
1 4028319 Conduit .......................................................................................... .. .. AR
2 2062875 Capscrew .......................................................................................... 2 2 2
3 1531558 Insert ................................................................................................. 2 2 2
4 1581836 Capscrew .......................................................................................... 2 2 2
5 4609349 Hose Clamp ....................................................................................... 2 2 2
6 4027909 Clamp ................................................................................................ 2 2 2
KEY:
A: 36 Volt
B: 48 Volt
C: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B C
7 1531557 Insert ................................................................................................. 1 1 1
8 1677721 Insert ................................................................................................. 1 1 1
9 ..... Contactors (FFigure 2-11)................................................................ .. .. ..
10 ..... Control Panels (FFigure 2-10).......................................................... .. .. ..
NOTES
BATTERY CONNECTOR
WITH FLAT OVERHEAD GUARD – LWB (E100-120XN) (11/2014 →)
KEY:
A: 36 Volt
B: 48 Volt
C: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B C
1 4098047 Battery Connector (SB) ..................................................................... 1 .. ..
1 4098156 Battery Connector (SB) ..................................................................... .. 1 ..
1 4098025 Battery Connector (SBE) ................................................................... 1 .. ..
1 4035983 Battery Connector ......................................................................... 1 .. ..
1 4098061 Battery Connector (SBE) ................................................................... .. 1 ..
1 4035984 Battery Connector ......................................................................... .. 1 ..
1 4098037 Battery Connector (SBE) ................................................................... .. .. 1
1 4035985 Battery Connector ......................................................................... .. .. 1
2 2062875 Capscrew .......................................................................................... 2 2 2
3 1531558 Insert ................................................................................................. 2 2 2
4 1581836 Capscrew .......................................................................................... 2 2 2
5 4609349 Hose Clamp ....................................................................................... 2 2 2
6 4027909 Clamp ................................................................................................ 2 2 2
7 1531557 Insert ................................................................................................. 1 1 1
8 1677721 Insert ................................................................................................. 1 1 1
9 ..... Contactors (FFigure 2-11)................................................................ .. .. ..
10 ..... Control Panels (FFigure 2-17).......................................................... .. .. ..
KEY:
A: 36 Volt
B: 48 Volt
C: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B C
1 4624453 Battery Connector (Assembly) (SB) .................................................. 1 .. ..
1 2065711 Battery Connector ......................................................................... 1 .. ..
1 4028319 Conduit .......................................................................................... AR .. ..
1 4624454 Battery Connector (Assembly) (SB) .................................................. .. 1 ..
1 2097782 Battery Connector ......................................................................... .. 1 ..
1 4028319 Conduit .......................................................................................... .. AR ..
1 4624455 Battery Connector (Assembly) (SBE) ................................................ 1 .. ..
1 4035983 Battery Connector ......................................................................... 1 .. ..
1 4028319 Conduit .......................................................................................... AR .. ..
1 4624456 Battery Connector (Assembly) (SBE) ................................................ .. 1 ..
1 4035984 Battery Connector ......................................................................... .. 1 ..
1 4028319 Conduit .......................................................................................... .. AR ..
1 4624457 Battery Connector (Assembly) (SBE) ................................................ .. .. 1
1 4035985 Battery Connector ......................................................................... .. .. 1
1 4028319 Conduit .......................................................................................... .. .. AR
2 2062875 Capscrew .......................................................................................... 2 2 2
3 1531558 Insert ................................................................................................. 2 2 2
4 1581836 Capscrew .......................................................................................... 2 2 2
5 4609349 Hose Clamp ....................................................................................... 2 2 2
6 4027909 Clamp ................................................................................................ 2 2 2
KEY:
A: 36 Volt
B: 48 Volt
C: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B C
7 1531557 Insert ................................................................................................. 1 1 1
8 1677721 Insert ................................................................................................. 1 1 1
9 ..... Contactors (FFigure 2-11)................................................................ .. .. ..
10 ..... Control Panels (FFigure 2-10).......................................................... .. .. ..
BATTERY CONNECTOR
WITH FLAT OVERHEAD GUARD – SWB (E80-100XNS) (11/2014 →)
KEY:
A: 36 Volt
B: 48 Volt
C: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B C
1 4098044 Battery Connector (SB) ..................................................................... 1 .. ..
1 4098150 Battery Connector (SB) ..................................................................... .. 1 ..
1 4098152 Battery Connector (SBE) ................................................................... 1 .. ..
1 4035983 Battery Connector ......................................................................... 1 .. ..
1 4098154 Battery Connector (SBE) ................................................................... .. 1 ..
1 4035984 Battery Connector ......................................................................... .. 1 ..
1 4098162 Battery Connector (SBE) ................................................................... .. .. 1
1 4035985 Battery Connector ......................................................................... .. .. 1
2 2062875 Capscrew .......................................................................................... 2 2 2
3 1531558 Insert ................................................................................................. 2 2 2
4 1581836 Capscrew .......................................................................................... 2 2 2
5 4609349 Hose Clamp ....................................................................................... 2 2 2
6 4027909 Clamp ................................................................................................ 2 2 2
7 1531557 Insert ................................................................................................. 1 1 1
8 1677721 Insert ................................................................................................. 1 1 1
9 ..... Contactors (FFigure 2-11)................................................................ .. .. ..
10 ..... Control Panels (FFigure 2-17).......................................................... .. .. ..
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a Not illustrated.
NOTES
CONTACTOR ASSEMBLY
UL-EE
CONTROLLER ASSEMBLY
PUMP MOTOR (→ 11/2014)
KEY:
A: 36/48 Volt
B: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B
1 2053858 Screw ......................................................................................................... 8 8
2 1565693 Guard ......................................................................................................... 2 2
3 4044470 Fan (36/48 VDC) ........................................................................................ 2 ..
3 4609751 Fan (12 Volt) .............................................................................................. .. 2
4 1683346 Insert .......................................................................................................... 8 8
5 4611032 Air Duct ...................................................................................................... 1 1
6 1500912 Clip ............................................................................................................. 2 2
7 1582464 Fastener ..................................................................................................... 2 2
8 4611033 Bracket ....................................................................................................... 1 1
9 132860 Capscrew ................................................................................................... 6 6
9 c 320162 Washer ....................................................................................................... 6 6
10 b 4609750 Controller (ACS4820-700AMPS) ............................................................... 1 ..
10 a 4611035 Controller (ACS4825-875AMPS) ............................................................... 1 ..
10 b 4609749 Controller (ACS8020-440AMPS) ............................................................... .. 1
10 a 4611037 Controller (ACS8025-550AMPS) ............................................................... .. 1
FOOTNOTES:
a E100-120XN/100XNS c Not Illustrated
b E80XN
CONTROLLER ASSEMBLY
TRACTION MOTOR (→ 11/2014)
KEY:
A: 36/48 Volt
B: 80 Volt
QTY
ITEM PART NO. DESCRIPTION A B
1 2053858 Screw ......................................................................................................... 8 8
2 1565693 Guard ......................................................................................................... 2 2
3 4044470 Fan (36/48 VDC) ........................................................................................ 2 ..
3 4609751 Fan (12 Volt) .............................................................................................. .. 2
4 1683346 Insert .......................................................................................................... 8 8
5 4611032 Air Duct ...................................................................................................... 1 1
6 1500912 Clip ............................................................................................................. 2 2
7 1582464 Fastener ..................................................................................................... 2 2
8 4611033 Bracket ....................................................................................................... 1 1
9 132860 Capscrew ................................................................................................... 6 6
9 320162 Washer ....................................................................................................... 6 6
10 4611036 Controller (ACS4825-1000AMPS) ............................................................. 1 ..
10 4611037 Controller (ACS8025-550AMPS) ............................................................... .. 1
CONTROLLER ASSEMBLY
PUMP AND TRACTION (11/2014 →)
KEY:
A: E80 XN 36/48V
B: E100 - 120 XN 36/48V
C: E80 XN 80V
D: E100 - 120 XN 80V
QTY
ITEM PART NO. DESCRIPTION A B C D
1 4628563 Controller-Motor ........................................................................ 1 .. .. ..
1 4628564 Controller-Motor ........................................................................ 1 2 .. ..
1 4627258 Controller-Motor ........................................................................ .. .. 1 ..
1 4627257 Controller-Motor ........................................................................ .. .. 1 2
2 ..... Bracket ...................................................................................... 2 2 2 2
3 4074820 Bracket ...................................................................................... 1 1 1 1
4 1527881 Capscrew .................................................................................. 8 8 8 8
5 1531557 Insert ......................................................................................... 12 12 12 12
6 4109993
1527879 Capscrew .................................................................................. 4 4 4 4
7 1480237 Nut (Fold Over) ......................................................................... 4 4 4 4
8 4085214 Air Duct ..................................................................................... 1 1 1 1
9 1527880 Capscrew .................................................................................. 4 4 4 4
10 1690977 Capscrew .................................................................................. 6 6 6 6
11 4044470 Fan (36/48 VDC) ....................................................................... 2 2 2 2
12 1565693 Guard ........................................................................................ 2 2 2 2
13 2053858 Screw ........................................................................................ 8 8 8 8
14 1683346 Insert ......................................................................................... 8 8 8 8
15 1582464 Fastener .................................................................................... 2 2 2 2
16 1500912 Clip ............................................................................................ 2 2 2 2
POWER CABLES
E80-100XNS (→ 11/2014)
POWER CABLES
E80-100XNS (11/2014 →)
POWER CABLES
E100-120XN (→ 11/2014)
POWER CABLES
E100-120XN (11/2014 →)
FOOTNOTES:
a → 10/2013 b 10/2013 →
DISPLAY
LOW MOUNT
FOOTNOTES:
a Not Illustrated
LIGHTS
ITEM PART NO. DESCRIPTION QTY
1 1672692 Screw .................................................................................................................. 2
2 4602052 Light (Tail) (LED) ................................................................................................ 2
2 2056826 Reflector (Tail) .................................................................................................... 2
3 1537551 Nut (Clip) ............................................................................................................. 2
4 2101031 Tail Light Base (RH) (FFigure 10-4).................................................................. 1
4 2101032 Tail Light Base (LH) (FFigure 10-4)................................................................... 1
5 4650809 Head/Work Light (Rear) ...................................................................................... 1
5 2098968 Worklight (Rear) (Halogen) ................................................................................. 1
6 1664407 Bracket ................................................................................................................ 1
7 1583611 Capscrew ............................................................................................................ 8
8 1531557 Insert ................................................................................................................... 8
9 2111852 Dome Light ......................................................................................................... 1
10 302027 Screw .................................................................................................................. 2
11 1683346 Insert ................................................................................................................... 2
12 1302024 Guard (Strobe Light) ........................................................................................... 1
13 1586428 Nut ...................................................................................................................... 2
14 1654013 Strobe Light Assembly ........................................................................................ 1
14 1652290 Strobe Light (Amber LED) .............................................................................. 1
14 ..... Connector Assembly ...................................................................................... 1
14 1561559 Connector (2 Pin) ....................................................................................... 1
14 1561755 Connector (Secondary Lock) ..................................................................... 1
14 1463138 Terminal Pin ............................................................................................... 2
15 1659602 Bracket ................................................................................................................ 1
16 1586759 Capscrew ............................................................................................................ 2
17 1470021 Bolt ...................................................................................................................... 2
18 320159 Washer ............................................................................................................... 2
19 1702892
4023408 Bracket (Front Work Lights) ................................................................................ 1
20 1702898
4023410 Bracket Wldmt (LH Front Work Light) ................................................................. 1
21 316836 Nut ...................................................................................................................... 2
22 2098969 Worklight (RH Front) (Glass Lens) (Halogen) ..................................................... 1
22 2098970 Worklight (LH Front) (Glass Lens) (Halogen) ..................................................... 1
22 4650810 Head/Work Light (Front RH LED) ....................................................................... 1
22 4650811 Head/Work Light (Front LH LED) ........................................................................ 1
23 1702897
4023409 Bracket Wldmt (RH) ............................................................................................ 1
24 1530243 Insert ................................................................................................................... 4
25 c 2109672 Wire Harness (RH Lights) (Standard Option) (FFigure 2-30)............................ 1
25 d 4626042 Wire Harness (RH Lights) (Standard Display without Turn Signals) (High Mount)
(FFigure 2-31)..................................................................................................... 1
25 d 4626043 Wire Harness (RH Lights) (Standard Option) (Low Mount) (FFigure 2-32)....... 1
25 c 2109673 Wire Harness (RH Lights) (Freezer Option) (FFigure 2-33).............................. 1
25 d 4625269 Wire Harness (RH Lights) (Freezer Option) (High Mount) (FFigure 2-34)........ 1
25 d 4626041 Wire Harness (RH Lights) (Freezer Option) (Low Mount) (FFigure 2-35)......... 1
26 c 4610582 Wire Harness (Lights) (LH) (FFigure 2-38)........................................................ 1
26 d 4625433 Wire Harness (LH Lights w/o Turn Signals) (FFigure 2-39).............................. 1
27 4616858 Wire Harness (Main Lights Chassis) (48V) (FFigure 2-58)............................... 1
27 4610567 Wire Harness (Main Lights Chassis) (80V) (FFigure 2-59)............................... 1
27 a 4610584 Wire Harness (Without Lights) (FFigure 2-60)................................................... 1
28 2100367 Relay (Mini) ......................................................................................................... 2
©2018 HYSTER COMPANY See Service Manual 2-51
for service procedures.
UNIT CODE A099
NORTH AMERICA 11/2018
LIGHTS
ITEM PART NO. DESCRIPTION QTY
28 a 2100367 Relay (Mini) ......................................................................................................... 1
29 4019192 Clip , Nut ............................................................................................................. 4
29 a 4019192 Clip , Nut ............................................................................................................. 3
30 296153 Capscrew ............................................................................................................ 4
30 a 296153 Capscrew ............................................................................................................ 3
31 4609161 Relay (Mini Power) ............................................................................................. 1
32 1606544 Clamp (Swivel) .................................................................................................... 1
33 1502066 Clamp (Swivel) .................................................................................................... 1
33 a 1573549 Clamp (Swivel) .................................................................................................... 1
34 2097858 Wire Harness (Front Switch) (FFigure 2-37)..................................................... 1
35 1382302 Switch ................................................................................................................. 1
36 1382304 Switch (Rear Work Light 12V) ............................................................................ 1
37 1654142 Grommet ............................................................................................................. 1
38 4079285 Bracket ................................................................................................................ 2
b 1463849 Lubricant ............................................................................................................. AR
FOOTNOTES:
a For Option with Strobe Light Only c → 10/2013
b Not Illustrated d 10/2013 →
NOTES
MINI-LEVER CONTROLS
3 FUNCTION
KEY:
A: Without Directional Control Switch
B: With Directional Control Switch
C: Without Directional Control Switch, With RTST
D: With Directional Control Switch, With RTST
QTY
ITEM PART NO. DESCRIPTION A B C D
1 2108514 Mini-Lever Assembly ................................................................ 1 .. .. ..
1 d 2108515 Mini-Lever Assembly ................................................................ 1 .. .. ..
1 2108517 Mini-Lever Assembly ................................................................ .. 1 .. ..
1 d 2108503 Mini-Lever Assembly ................................................................ .. 1 .. ..
1 2108499 Mini-Lever Assembly ................................................................ .. .. 1 ..
1 d 2108500 Mini-Lever Assembly ................................................................ .. .. 1 ..
1 2108505 Mini-Lever Assembly ................................................................ .. .. .. 1
1 d 2108519 Mini-Lever Assembly ................................................................ .. .. .. 1
2 ..... Lever Position 1 .................................................................... 1 1 1 1
2 2110791 Lever (Single Function) .................................................... 1 1 1 1
3 ..... Lever Position 2 .................................................................... 1 1 1 1
3 2110791 Lever (Single Function) .................................................... 1 1 .. ..
3 2110793 Lever (With Override) ....................................................... .. .. 1 1
4 ..... Lever Position 3 .................................................................... 1 1 1 1
4 2110791 Lever (Single Function) .................................................... 1 1 1 1
4 2110792 Lever (Clamping) .............................................................. 1 1 1 1
5 ..... Lever Position 4 .................................................................... 1 1 1 1
5 2108249 Plug .................................................................................. 1 1 1 1
6 f 2111799 Armrest (Without Push Buttons) ........................................... 1 1 .. ..
6 4603439 Armrest (With Push Buttons) ................................................ 1 1 1 1
7 2111769 Cushion (Armrest) ................................................................ 1 1 1 1
8 1709587 Nut .................................................................................... 5 5 5 5
9 1703513 Screw .................................................................................... 9 9 9 9
10 2111801 Wire Harness ........................................................................ 1 1 1 1
11 2111768 Switch (E-Stop) (Emergency Switch) ................................... 1 1 1 1
12 a 2107320 Push Button Switch (Emergency Disconnect) .................. 1 1 1 1
12 4180406 Block Push Button Contact .......................................... 1 1 1 1
13 a 1704528 Push Button (Position 3) ....................................................... 1 .. .. ..
13 a 1704528 Push Button (Position 2) ....................................................... .. 1 .. ..
13 a d 1704528 Push Button (Position 2 and 3) ............................................. .. .. 2 2
13 b c 1705359 Cover (Push Button) ............................................................. AR AR AR AR
14 e 1704529 Wire Harness (Forward/Reverse Switch in the MLM) .......... 1 1 1 1
15 2111802
4605337 Printed Circuit Board ............................................................ 1 1 1 1
16 2111800 Cover (Bottom Armrest) ........................................................ 1 1 1 1
17 2111770 Horn Button .......................................................................... 1 1 1 1
18 2110943 Switch (Directional Control) .................................................. .. 1 .. 1
19 2110942 Plug (Directional Control Switch) .......................................... 1 .. 1 ..
20 1698449 Capscrew .............................................................................. 8 8 8 8
FOOTNOTES:
a Not all Lift Trucks may have all the switches and d With Clamping
buttons shown. e With RTST/With Clamping
b Not Illustrated f Without Clamping
c Plug for Use Without Push Button
NOTES
MINI-LEVER CONTROLS
4 FUNCTION
KEY:
A: Without Directional Control Switch
B: With Directional Control Switch
C: Without Directional Control Switch, With RTST
D: With Directional Control Switch, With RTST
QTY
ITEM PART NO. DESCRIPTION A B C D
1 2108497 Mini-Lever Assembly ................................................................ 1 .. .. ..
1 e 2108498 Mini-Lever Assembly ................................................................ 1 .. .. ..
1 2108502 Mini-Lever Assembly ................................................................ .. 1 .. ..
1 e 2108504 Mini-Lever Assembly ................................................................ .. 1 .. ..
1 2108516 Mini-Lever Assembly ................................................................ .. .. 1 ..
1 e 2108501 Mini-Lever Assembly ................................................................ .. .. 1 ..
1 2108518 Mini-Lever Assembly ................................................................ .. .. .. 1
1 e 2108506 Mini-Lever Assembly ................................................................ .. .. .. 1
2 ..... Lever Position 1 .................................................................... 1 1 1 1
2 2110791 Lever (Single Function) .................................................... 1 1 1 1
3 ..... Lever Position 2 .................................................................... 1 1 1 1
3 2110791 Lever (Single Function) .................................................... 1 1 .. ..
3 2110793 Lever (With Override) ....................................................... .. .. 1 1
4 ..... Lever Position 3 .................................................................... 1 1 1 1
4 2110791 Lever (Single Function) .................................................... 1 1 1 1
5 ..... Lever Position 4 .................................................................... 1 1 1 1
5 2110791 Lever (Single Function) .................................................... 1 1 .. ..
5 2110792 Lever (Clamping) .............................................................. .. .. 1 1
6 f 2111799 Armrest (Without Push Buttons) ........................................... 1 1 .. ..
6 4603439 Armrest (With Push Buttons) ................................................ 1 1 1 1
7 2111769 Cushion (Armrest) ................................................................ 1 1 1 1
8 1709587 Nut .................................................................................... 5 5 5 5
9 1703513 Screw .................................................................................... 9 9 9 9
10 2111801 Wire Harness ........................................................................ 1 1 1 1
11 2111768 Switch (E-Stop) (Emergency Switch) ................................... 1 1 1 1
12 a 2107320 Push Button Switch (Emergency Disconnect) .................. 1 1 1 1
12 4180406 Block Push Button Contact .......................................... 1 1 1 1
13 a e 1704528 Push Button (Position 4) ....................................................... 1 1 .. ..
13 a 1704528 Push Button (Position 2) ....................................................... .. .. 1 1
13 a e 1704528 Push Button (Position 2 and 4) ............................................. .. .. 1 1
13 b c 1705359 Cover (Push Button) ............................................................. AR AR AR AR
14 d 1704529 Wire Harness (Forward/Reverse Switch in the MLM) .......... 1 1 1 1
15 2111802
4605337 Printed Circuit Board ............................................................ 1 1 1 1
16 2111800 Cover (Bottom Armrest) ........................................................ 1 1 1 1
17 2111770 Horn Button .......................................................................... 1 1 1 1
18 2110943 Switch (Directional Control) .................................................. .. 1 .. 1
19 2110942 Plug (Directional Control Switch) .......................................... 1 .. 1 ..
20 1698449 Capscrew .............................................................................. 8 8 8 8
FOOTNOTES:
a Not all Lift Trucks may have all the switches and d RTST With Clamping
buttons shown. e With Clamping
b Not Illustrated f Without Clamping
c Plug for Use Without Push Button
WIRE HARNESS
RH LIGHTS – FREEZER OPTION (→ 10/2013)
WIRE HARNESS
LIGHTS – LEFT HAND (→ 10/2013)
WIRE HARNESS
LEFT HAND – WITHOUT TURN SIGNALS (10/2013 →)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 1 OF 3 (→ 11/2014)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 1 OF 3 (→ 11/2014)
NOTES
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 2 OF 3 (→ 11/2014)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 2 OF 3 (→ 11/2014)
NOTES
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 3 OF 3 (→ 11/2014)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 3 OF 3 (→ 11/2014)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 3 OF 3 (→ 11/2014)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 1 OF 3 (11/2014 ↔ 11/2015)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 1 OF 3 (11/2014 ↔ 11/2015)
NOTES
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 2 OF 3 (11/2014 ↔ 11/2015)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 2 OF 3 (11/2014 ↔ 11/2015)
NOTES
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 3 OF 3 (11/2014 ↔ 11/2015)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 3 OF 3 (11/2014 ↔ 11/2015)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 3 OF 3 (11/2014 ↔ 11/2015)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 1 OF 3 (11/2015 →)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 2 OF 3 (11/2015 →)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 2 OF 3 (11/2015 →)
NOTES
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 3 OF 3 (11/2015 →)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 3 OF 3 (11/2015 →)
WIRE HARNESS
MAIN – MANUAL HYDRAULIC SHEET 3 OF 3 (11/2015 →)
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 1 OF 3 (→ 11/2014)
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 1 OF 3 (→ 11/2014)
NOTES
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 2 OF 3 (→ 11/2014)
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 2 OF 3 (→ 11/2014)
NOTES
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 3 OF 3 (→ 11/2014)
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 3 OF 3 (→ 11/2014)
NOTES
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 1 OF 3 (11/2014 ↔ 11/2015)
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 1 OF 3 (11/2014 ↔ 11/2015)
NOTES
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 2 OF 3 (11/2014 ↔ 11/2015)
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 2 OF 3 (11/2014 ↔ 11/2015)
NOTES
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 3 OF 3 (11/2014 ↔ 11/2015)
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 3 OF 3 (11/2014 ↔ 11/2015)
NOTES
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 1 OF 3 (11/2015 →)
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 1 OF 3 (11/2015 →)
NOTES
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 2 OF 3 (11/2015 →)
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 2 OF 3 (11/2015 →)
NOTES
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 3 OF 3 (11/2015 →)
WIRE HARNESS
MAIN – ELECTRO-HYDRAULIC SHEET 3 OF 3 (11/2015 →)
NOTES
WIRE HARNESS
MAIN LIGHTS CHASSIS – 48V
WIRE HARNESS
MAIN LIGHTS CHASSIS – 48V
NOTES
WIRE HARNESS
MAIN LIGHTS CHASSIS – 80V
WIRE HARNESS
MAIN LIGHTS CHASSIS – 80V
NOTES
WIRE HARNESS
MAIN CHASSIS – W/O LIGHTS
NOTES
WIRE HARNESS
SEAT – E-HYDRAULIC
NOTES
WIRE HARNESS
STEERING COLUMN
NOTES
3 DRIVE UNIT
UNIT CODE A099
11/2018 NORTH AMERICA
SECTION 3
DRIVE UNIT
DESCRIPTION PAGE
DIFFERENTIAL ASSEMBLY
WET BRAKE ............................................................................................................................................... 3-23
DRIVE AXLE AND ATTACHING PARTS ........................................................................................................ 3-2
DRIVE AXLE ASSEMBLY
WET BRAKE - RIGHT AND LEFT HAND HUBS (→ 2/2015) .................................................................... 3-4
WET BRAKE - RIGHT AND LEFT HAND HUBS (2/2015 →) .................................................................... 3-8
WET BRAKE - BRAKES AND DIFFERENTIAL (→ 2/2015) ...................................................................... 3-12
WET BRAKE - BRAKES AND DIFFERENTIAL (2/2015 →) ...................................................................... 3-16
WET BRAKE - INPUT PINION CARRIER (→ 2/2015) ............................................................................... 3-19
WET BRAKE - INPUT PINION CARRIER (2/2015 →) ............................................................................... 3-21
DRIVE TIRE AND WHEEL
E100-120XN ................................................................................................................................................ 3-26
E80XN-100XNS .......................................................................................................................................... 3-25
TRACTION MOTOR ........................................................................................................................................ 3-24
KEY:
A: E80XN-100XNS
B: E100-120XN
QTY
ITEM PART NO. DESCRIPTION A B
1 1527889 Capscrew ................................................................................................... 1 1
2 221739 Washer ....................................................................................................... 1 1
3 284373 Motor Mount ............................................................................................... 1 1
4 4611214 Bracket ....................................................................................................... 1 1
5 1370949
1528888 Nut (Shoulder) ............................................................................................ 1 1
6 1527886 Capscrew ................................................................................................... 2 2
7 1460477 Nut .............................................................................................................. 2 2
8 4609346 Traction Motor (AC 36/48V) (FFigure 3-9)................................................ 1 1
8 4609345 Traction Motor (AC 80V) (FFigure 3-9)..................................................... 1 1
9 1683525 O-Ring ........................................................................................................ 1 1
10 193000 Snap Ring .................................................................................................. 1 1
11 4614434 Coupler ....................................................................................................... 1 1
12 1527892 Capscrew ................................................................................................... 10 10
13 1692643 Plug (Breather) ........................................................................................... 1 1
14 4018064 Capscrew ................................................................................................... 4 4
15 296434 Washer ....................................................................................................... 4 4
16 292660 Nut .............................................................................................................. 4 4
17 376026 Wheel Nut .................................................................................................. 16 16
18 b 4617722 Drive Axle (Wet) (FFigure 3-4, FFigure 3-6, FFigure 3-2)...................... 1 ..
18 b 4617723 Drive Axle (Wet) (FFigure 3-4, FFigure 3-6, FFigure 3-2)...................... .. 1
18 c 4642004 Drive Axle (Wet) (FFigure 3-3, FFigure 3-5, FFigure 3-7)...................... 1 ..
KEY:
A: E80XN-100XNS
B: E100-120XN
QTY
ITEM PART NO. DESCRIPTION A B
18 c 4642005 Drive Axle (Wet) (FFigure 3-3, FFigure 3-5, FFigure 3-7)...................... .. 1
a 1703667 Kit-Motor Band ........................................................................................... 1 1
FOOTNOTES:
a Not Illustrated c 2/2015 →
b → 2/2015
NOTES
NOTES
FOOTNOTES:
a Not Illustrated b Optional
NOTES
FOOTNOTES:
a Located on Differential Shaft e → 6/2016
b Not Illustrated f 4/2016 →
c Service with 4650812 Service Brake Assembly g 6/2016 →
d → 4/2016
KEY:
A: E80XN-100XNS
B: E100-120XN
QTY
ITEM PART NO. DESCRIPTION A B
4617722 Drive Axle (Wet) ......................................................................................... 1 ..
4617723 Drive Axle (Wet) ......................................................................................... .. 1
1 4034747 Drive Axle Housing (RH) ........................................................................ 1 1
2 2101125 Shim ....................................................................................................... 1 1
3 2101126 Shim ....................................................................................................... 1 1
4 2101127 Shim ....................................................................................................... 1 1
5 2101128 Shim ....................................................................................................... 1 1
6 2101129 Shim ....................................................................................................... 1 1
7 2101124 Shim ....................................................................................................... 1 1
8 4023215 Carrier (Assembly) ................................................................................. 1 1
9 4022987 Pinion ................................................................................................ 1 1
10 230420 Bearing Cone .................................................................................... 1 1
11 230419 Bearing Cup ...................................................................................... 1 1
12 1672691 Washer .............................................................................................. 1 1
13 39756 O-Ring ............................................................................................... 1 1
14 4609330 Carrier (Input Pinion) ......................................................................... 1 1
15 a 4605834 Washer .............................................................................................. 11 11
16 a 293632 Capscrew .......................................................................................... 11 11
17 2050733 Nut ..................................................................................................... 1 1
18 1672693 Sleeve ............................................................................................... 1 1
19 2022352 Tapered Roller Bearing ..................................................................... 1 1
KEY:
A: E80XN-100XNS
B: E100-120XN
QTY
ITEM PART NO. DESCRIPTION A B
20 2050732 Lockwasher ....................................................................................... 1 1
FOOTNOTES:
a Not Included with Input Pinion Carrier Assembly
KEY:
A: E80XN-100XNS
B: E100-120XN
QTY
ITEM PART NO. DESCRIPTION A B
4642004 Drive Axle (Wet) ......................................................................................... 1 ..
4642005 Drive Axle (Wet) ......................................................................................... .. 1
1 4034747 Drive Axle Housing (RH) ........................................................................ 1 1
2 2101125 Shim ....................................................................................................... 1 1
3 2101126 Shim ....................................................................................................... 1 1
4 2101127 Shim ....................................................................................................... 1 1
5 2101128 Shim ....................................................................................................... 1 1
6 2101129 Shim ....................................................................................................... 1 1
7 2101124 Shim ....................................................................................................... 1 1
8 4023215 Carrier (Assembly) ................................................................................. 1 1
9 4022987 Pinion ................................................................................................ 1 1
10 230420 Bearing Cone .................................................................................... 1 1
11 230419 Bearing Cup ...................................................................................... 1 1
12 1672691 Washer .............................................................................................. 1 1
13 39756 O-Ring ............................................................................................... 1 1
14 4609330 Carrier (Input Pinion) ......................................................................... 1 1
15 a 4605834 Washer .............................................................................................. 11 11
16 a 293632 Capscrew .......................................................................................... 11 11
17 2050733 Nut ..................................................................................................... 1 1
18 1672693 Sleeve ............................................................................................... 1 1
19 2022352 Tapered Roller Bearing ..................................................................... 1 1
KEY:
A: E80XN-100XNS
B: E100-120XN
QTY
ITEM PART NO. DESCRIPTION A B
20 2050732 Lockwasher ....................................................................................... 1 1
FOOTNOTES:
a Not Included with Input Pinion Carrier Assembly
FOOTNOTES:
a Located on Shaft c 4/2016 →
b → 4/2016
KEY:
A: With Non-Marking Tire
B: With Smooth Rubber Tire
C: With Lug-Tread Tire
QTY
ITEM PART NO. DESCRIPTION A B C
1 1656323 Wheel And Tire (Assembly) (Standard Tread) .................................. 2 .. ..
1 1656324 Wheel And Tire (Assembly) (Wide Tread) ......................................... 2 .. ..
1 1541513 Wheel And Tire (Assembly) (Standard Tread) .................................. .. 2 ..
1 1541514 Wheel And Tire (Assembly) (Wide Tread) ......................................... .. 2 ..
2 1539313 Wheel (Standard Tread) ................................................................ 1 1 ..
2 1539315 Wheel (Wide Tread) ...................................................................... 1 1 ..
3 1655310 Cushion Tire .................................................................................. 1 .. ..
3 1541525 Cushion Tire .................................................................................. .. 1 ..
4 1541518 Wheel And Tire (Assembly) (Standard Tread) .................................. .. .. 2
4 1541517 Wheel And Tire (Assembly) (Wide Tread) ......................................... .. .. 2
5 1539313 Wheel (Standard Tread) ................................................................ .. .. 1
5 1539315 Wheel (Wide Tread) ...................................................................... .. .. 1
6 1541527 Cushion Tire .................................................................................. .. .. 1
KEY:
A: With Non-Marking Tire
B: With Smooth Rubber Tire
C: With Lug-Tread Tire
QTY
ITEM PART NO. DESCRIPTION A B C
1 1656210 Wheel And Tire (Assembly) (Standard Tread) .................................. 2 .. ..
1 1656211 Wheel And Tire (Assembly) (Wide Tread) ......................................... 2 .. ..
1 1541519 Wheel And Tire (Assembly) (Standard Tread) .................................. .. 2 ..
1 1541520 Wheel And Tire (Assembly) (Wide Tread) ......................................... .. 2 ..
2 1539317 Wheel (Standard Tread) ................................................................ 1 1 ..
2 1539319 Wheel (Wide Tread) ...................................................................... 1 1 ..
3 1655318 Cushion Tire .................................................................................. 1 .. ..
3 1541528 Cushion Tire .................................................................................. .. 1 ..
4 1541523 Wheel And Tire (Assembly) (Standard Tread) .................................. .. .. 2
4 1541524 Wheel And Tire (Assembly) (Wide Tread) ......................................... .. .. 2
5 1539317 Wheel (Standard Tread) ................................................................ .. .. 1
5 1539319 Wheel (Wide Tread) ...................................................................... .. .. 1
6 1541530 Cushion Tire .................................................................................. .. .. 1
4 STEERING SYSTEM
UNIT CODE A099
11/2018 NORTH AMERICA
SECTION 4
STEERING SYSTEM
DESCRIPTION PAGE
STEER AXLE
WITHOUT SENSOR ................................................................................................................................... 4-2
STEER AXLE CYLINDER ............................................................................................................................... 4-6
STEER PUMP ASSEMBLY
→ 11/2014 .................................................................................................................................................. 4-16
11/2014 → .................................................................................................................................................. 4-18
STEER TIRE AND WHEEL ............................................................................................................................. 4-8
STEERING ACCUMULATOR ......................................................................................................................... 4-20
STEERING COLUMN ASSEMBLY
FIXED (→ 10/2013) .................................................................................................................................... 4-11
FIXED (10/2013 →) .................................................................................................................................... 4-12
TELESCOPIC (→ 10/2013) ........................................................................................................................ 4-14
TELESCOPIC (10/2013 →) ........................................................................................................................ 4-15
STEERING WHEEL AND COLUMN
FIXED .......................................................................................................................................................... 4-9
TELESCOPIC .............................................................................................................................................. 4-10
STEER AXLE
WITHOUT SENSOR
STEER AXLE
WITHOUT SENSOR
FOOTNOTES:
a Greased c With Greased Bushing
b Teflon d With Teflon Bushing
NOTES
KEY:
A: E80XN (18x6x12-1/8)
B: E80-120XN/E100XNS (18x7x12-1/8)
QTY
ITEM PART NO. DESCRIPTION A B
375333 Wheel and Tire (Smooth Tread Electric Compound) ................................. 2
375335 Wheel and Tire (Lug Tread Electric Compound) ....................................... 2
1655997 Wheel And Tire (Lug Tread Non-Marking) ................................................. 2 ..
1541537 Wheel And Tire (Plain Tread Standard Compound) .................................. .. 2
1541538 Wheel And Tire (Lug Tread) ....................................................................... .. 2
1656212 Wheel And Tire (Plain Tread Non-Marking) ............................................... .. 2
1 370444 Wheel ..................................................................................................... .. 2
2 806223 Cushion Tire (Lug Tread Electric Compound) ....................................... 1 ..
2 259648 Cushion Tire (Smooth Tread Electric Compound) ................................. 1 ..
2 1655316 Cushion Tire (Plain Tread Non Marking) ............................................... 1 ..
2 1541486 Cushion Tire (Smooth) (Plain Tread Standard Compound) ................... .. 1
2 1541490 Cushion Tire (Lug Tread) ....................................................................... .. 1
2 1655317 Cushion Tire (Plain Tread Non-Marking) ............................................... .. 1
a 376026 Wheel Nut .................................................................................................. 16 16
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a → 10/2013 c 10/2013 →
b → 11/2014 d 11/2014 →
FOOTNOTES:
a → 10/2013 c 10/2013 →
b → 11/2014 d 11/2014 →
5 BRAKE/ACCELERATOR SYSTEM
UNIT CODE A099
11/2018 NORTH AMERICA
SECTION 5
BRAKE/ACCELERATOR SYSTEM
DESCRIPTION PAGE
BRAKE SYSTEM
ITEM PART NO. DESCRIPTION QTY
1 ..... Actuator Assembly .............................................................................................. 1
1 4119571 Kit-Park Brake Actuator .................................................................................. 1
2 1510113 Capscrew ............................................................................................................ 1
3 1487063 Fitting .................................................................................................................. 1
4 1391432 Clamp ................................................................................................................. 1
5 1393879 Nut ...................................................................................................................... 1
6 4051091 Rod End .............................................................................................................. 1
7 153 Pin ....................................................................................................................... 1
8 1530011 Pin , Cotter .......................................................................................................... 1
9 4614915 Hose Assy (Actuator) .......................................................................................... 1
10 1527880 Capscrew ............................................................................................................ 2
11 4051087 Plate .................................................................................................................... 2
12 221573 Capscrew ............................................................................................................ 1
13 221771 Washer ............................................................................................................... 2
14 15117 Locknut ............................................................................................................... 1
15 15028 Nut ...................................................................................................................... 1
16 1527888 Capscrew ............................................................................................................ 3
17 1370949
1528888 Nut (Shoulder) .................................................................................................... 3
18 1646439 Reservoir Assembly (Mineral Oil) ....................................................................... 1
18 2314223 Reservoir (Assembly) ..................................................................................... 1
18 2021341 Cap ............................................................................................................. 1
18 2077604 Tank Assembly ........................................................................................... 1
18 2021343 Packing ...................................................................................................... 1
18 1645381 Diaphragm ...................................................................................................... 1
18 1646397 Cap ................................................................................................................. 1
19 2021353 Holder , Reservoir Tank ...................................................................................... 1
20 1510126 Screw (Button Head) .......................................................................................... 1
21 325182 Nut , Foldover ..................................................................................................... 1
22 1486738 Fitting .................................................................................................................. 1
23 2111658 Hose Assy ........................................................................................................... 1
24 1659021 Hose (Low Pressure) .......................................................................................... 1
25 166857 Clamp ................................................................................................................. 2
26 166285 Clamp ................................................................................................................. 1
27 1614087 Insert ................................................................................................................... 1
28 1527878 Capscrew ............................................................................................................ 1
29 ..... Brake Assembly (FFigure 5-2)........................................................................... 1
30 4616137 Hose Assy (Park Brake) ..................................................................................... 1
31 4613409 Hose Assy (Brake Supply) .................................................................................. 1
32 a 1487063 Fitting .................................................................................................................. 1
32 b 1486578 Fitting .................................................................................................................. 1
33 b 4101196 Fitting .................................................................................................................. 1
FOOTNOTES:
a → 4/2014 b 4/2014 →
BRAKE ASSEMBLY
ITEM PART NO. DESCRIPTION QTY
1 1673283 Pad (Brake Pedal) .............................................................................................. 1
2 4035941 Pedal Assy .......................................................................................................... 1
3 4025497 Bushing .......................................................................................................... 2
4 1582301 Spring (Inner) ...................................................................................................... 1
4 1582300 Spring (Outer) ..................................................................................................... 1
5 292571 Capscrew ............................................................................................................ 1
6 296427 Washer ............................................................................................................... 1
7 4025179 Tube .................................................................................................................... 1
8 4042993 Mounting Weldment ............................................................................................ 1
9 1586436 Nut ...................................................................................................................... 1
10 1527884 Capscrew ............................................................................................................ 1
11 1593336 Nut ...................................................................................................................... 2
12 4019192 Clip , Nut ............................................................................................................. 1
13 1693441 Clip ...................................................................................................................... 1
14 296152 Capscrew ............................................................................................................ 1
15 4040181 Handle (Pump) .................................................................................................... 1
16 4040177 Parking Brake Valve (FFigure 5-3).................................................................... 1
17 1677833 Screw .................................................................................................................. 1
18 1480237 Nut (Fold Over) ................................................................................................... 2
19 4031645 Handle (Valve) .................................................................................................... 1
20 1486740 Fitting .................................................................................................................. 1
20 6992657
265787 O-Ring ............................................................................................................ 1
21 1490533 Fitting .................................................................................................................. 1
22 a 1487063 Fitting .................................................................................................................. 1
22 b 1486578 Fitting .................................................................................................................. 1
23 4083394 Setscrew ............................................................................................................. 1
24 296018 Capscrew ............................................................................................................ 2
25 4040621 Master Cylinder (FFigure 5-4)........................................................................... 1
26 1707679
4083331 Pressure Transducer .......................................................................................... 1
27 1460477 Nut ...................................................................................................................... 2
28 1527884 Capscrew ............................................................................................................ 2
29 1378435 Pin ....................................................................................................................... 1
30 1351689 Locking Cotter Pin .............................................................................................. 1
31 1487058 Fitting .................................................................................................................. 1
FOOTNOTES:
a → 4/2014 b 4/2014 →
NOTES
6 HYDRAULIC SYSTEM
UNIT CODE A099
11/2018 NORTH AMERICA
SECTION 6
HYDRAULIC SYSTEM
DESCRIPTION PAGE
FOOTNOTES:
a Not Illustrated b Without Mast
FOOTNOTES:
a Service with Kit 1707195 Filter Element and Cap c With Vent Line
Seal d Without Vent Line (Not Shown)
b With System Monitoring Option
HYDRAULIC HOSES
STEERING
KEY:
A: With Fixed Steering Column
B: With Telescopic Steering Column
QTY
ITEM PART NO. DESCRIPTION A B
1 1384698 Clamp ......................................................................................................... 1 1
2 4616852 Hose Assy (Steering Supply) ..................................................................... 1 ..
2 4616851 Hose Assy (Steering Supply) ..................................................................... .. 1
3 4609572 Hose Assy (Steering Return) ..................................................................... 1 ..
3 4609388 Hose Assy (Steering Return) ..................................................................... .. 1
4 4609502 Hose Assy (Steering Load Sense) ............................................................. 1 ..
4 4609384 Hose Assy (Steering Load Sense) ............................................................. .. 1
5 4609504 Hose Assy (Steer Axle) .............................................................................. 2 ..
5 4609387 Hose Assy (Steer Axle) .............................................................................. .. 2
6 325182 Nut , Foldover ............................................................................................. 3 3
7 4609650 Bracket ....................................................................................................... 2 2
8 1527876 Capscrew ................................................................................................... 3 3
9 1393879 Nut .............................................................................................................. 1 1
10 176454 Clamp ......................................................................................................... 1 1
11 1510113 Capscrew ................................................................................................... 1 1
12 b 4609383 Hose Assy (Steer Axle) .............................................................................. 2 2
12 a 4610375 Hose Assy (Steer Axle) .............................................................................. 2 2
13 176454 Clamp ......................................................................................................... 3 3
14 1480237 Nut (Fold Over) .......................................................................................... 1 1
15 4109993
1527879 Capscrew ................................................................................................... 1 1
16 1528587 Fitting ......................................................................................................... 2 2
17 4024213 Fitting ......................................................................................................... 2 2
18 1707283 Hose Clamp ............................................................................................... 1 1
19 287844 Capscrew ................................................................................................... 1 1
20 313805 Nut .............................................................................................................. 1 1
21 1393879 Nut .............................................................................................................. 2 2
22 1527880 Capscrew ................................................................................................... 2 2
23 4032052 Bracket ....................................................................................................... 1 1
24 1614087 Insert .......................................................................................................... 2 2
25 1527878 Capscrew ................................................................................................... 2 2
26 ..... Control Valve And Fittings (FFigure 6-13, FFigure 6-17)......................... 1 1
27 ..... Steer Axle Cylinder (FFigure 4-2)............................................................. 1 1
28 ..... Steering Pump Assembly (FFigure 4-10).................................................. 1 1
FOOTNOTES:
a E100-120XN b E80-100XNS
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated c 11/2014 →
b → 11/2014
HYDRAULIC PUMP
29 CC (11/2014 →)
FOOTNOTES:
a Not Illustrated
HYDRAULIC PUMP
33 CC
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a 48V Motor c Not Illustrated
b 80V Motor
NOTES
NOTES
FOOTNOTES:
a Not Illustrated b Without Aux. 2 Lever
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1516202 Fitting (Three and Four Function Hoses) ................................................... 2 4
2 6996681
1473887 Fitting (Tilt Hoses) ...................................................................................... 2 2
2 1495113
265731 O-Ring ................................................................................................... 1 1
3 1528596 Fitting ......................................................................................................... 1 1
4 1486740 Fitting (Steering Return Hose) ................................................................... 1 1
4 6992657
265787 O-Ring ................................................................................................... 1 1
5 1579809
222443 Fitting ......................................................................................................... 1 1
5 16483 O-Ring ................................................................................................... 1 1
6 98599 Fitting (Return Hose) .................................................................................. 1 1
6 1450764
16486 O-Ring ................................................................................................... 1 1
7 6996684
1486751 Fitting (Supply Hose) .................................................................................. 1 1
8 1516199 Fitting (Brake Supply Hose) ....................................................................... 1 1
9 a 1704570 Check Valve ............................................................................................... 1 1
9 b 1486740 Fitting ......................................................................................................... 1 1
9 6992657 O-Ring ................................................................................................... 1 1
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
265787
10 a 1487097 Fitting (Steering Supply Hose) ................................................................... 1 1
11 2094702 Hydraulic Control Valve (Without Clamping) (FFigure 6-14)..................... 1 ..
11 2094703 Hydraulic Control Valve (Without Clamping) (FFigure 6-14)..................... .. 1
11 2098809 Hydraulic Control Valve (With Clamping) (FFigure 6-14).......................... 1 ..
11 2098812 Hydraulic Control Valve (With Clamping) (FFigure 6-14).......................... .. 1
FOOTNOTES:
a → 11/2013 b 11/2013 →
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
2094702 Hydraulic Control Valve (Without Clamping) .............................................. 1 ..
2094703 Hydraulic Control Valve (Without Clamping) .............................................. .. 1
2098809 Hydraulic Control Valve (With Clamping) ................................................... 1 ..
2098812 Hydraulic Control Valve (With Clamping) ................................................... .. 1
1 1701855
4645087 Solenoid - M-HYD locking ...................................................................... AR AR
2 1701656 Valve Section (Aux.) (Without Clamping) (FFigure 6-15)..................... 1 1
2 1701669 Valve Section (Aux.) (With Clamping) (FFigure 6-15).......................... 1 1
3 1701667 Valve Section (Dual Aux.) (FFigure 6-15)............................................. .. 1
4 1701664
4068231 Valve Section (Tilt) (FFigure 6-15)....................................................... 1 1
5 1696312 Lowering Control Valve .......................................................................... 1 1
6 1701662 Valve Section (Lift) (FFigure 6-15)....................................................... 1 1
7 1696204
4068228 Relief Valve (Main) (Without Clamping) ................................................. 1 1
7 1701672 Relief Valve (Main) (With Clamping) ...................................................... .. 1
8 1701670 Valve Section (Inlet) (FFigure 6-16)..................................................... 1 1
9 1696043 Tie Rod Kit ............................................................................................. 1 ..
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
9 1695985 Tie Rod .................................................................................................. .. 1
10 1701817 Kit-Connector ......................................................................................... 1 1
11 1696301
1703511
4069956
4132001 Relief Valve ............................................................................................ 1 1
12 1701654 Kit-Sensor .............................................................................................. AR AR
a 1701655 Kit-Seal .................................................................................................. 1 1
FOOTNOTES:
a Not Illustrated
NOTES
FOOTNOTES:
a → 11/2013 b 11/2013 →
FOOTNOTES:
a Contains 1 of Kit 1696414 and 5 of Kit 1696266
FOOTNOTES:
a Electronic
TILT CYLINDER
KEY:
A: 5 Degrees Forward/5 Degrees Back
B: 8 Degrees Forward/5 Degrees Back
QTY
ITEM PART NO. DESCRIPTION A B
4624489 Tilt Cylinder ................................................................................................ 1 ..
2066237 Cylinder Assy ............................................................................................. .. 1
1 193554 Rod Wiper .............................................................................................. 1 1
2 1381049 Gland ..................................................................................................... 1 1
3 638248 Back-Up Ring ......................................................................................... 1 1
4 1381085 Rod Seal ................................................................................................ 1 1
5 334155 Wear Ring .............................................................................................. 1 1
6 1317007 Back-Up Ring ......................................................................................... 1 1
7 15884 O-Ring ................................................................................................... 1 1
8 1383056 Cylinder Rod .......................................................................................... 1 ..
8 1383057 Cylinder Rod .......................................................................................... .. 1
9 199917 O-Ring ................................................................................................... 1 1
10 2044378 Piston Seal ............................................................................................. 1 1
11 318067 Wear Ring .............................................................................................. 1 1
12 1380897 Piston ..................................................................................................... 1 1
13 2036547 Locknut .................................................................................................. 1 1
14 1559452 Tube Wldmt-Cylinder ............................................................................. 1 1
15 4062462 Spacer ................................................................................................... 1 ..
1378677 Kit-Seal ....................................................................................................... 1 1
NOTES
SECTION 7
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-18
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-20
INNER MAST
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-4
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT (→ 10/2013) ...................................................................................... 7-6
TWO STAGE LIMITED FREE-LIFT (10/2013 →) ...................................................................................... 7-10
MAIN LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT - E80XN .............................................................................................. 7-14
TWO STAGE LIMITED FREE-LIFT - E100-120XN/E100XNS .................................................................... 7-16
OUTER MAST
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 7-2
OUTER MAST
TWO STAGE LIMITED FREE-LIFT
E80XN
E100-120XN/E100XNS
KEY:
A: E80XN
B: E100-120XN/E100XNS
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Mast Assy ................................................................................................... 1 1
1 a. . . . . Outer Mast ............................................................................................. 1 1
2 1500744 Stubshaft ........................................................................................... 2 2
3 b 1399203 Load Roller ("A") (126.75/126.49) .......................................................... 2 2
3 1399204 Load Roller ("B") (127.51/127.25) .......................................................... 2 2
3 1399205 Load Roller ("C") (128.27/128.01) ......................................................... 2 2
4 1465072 Snap Ring .............................................................................................. 2 2
5 16002 Grease Fitting ........................................................................................ 2 2
6 1507004 Bushing .................................................................................................. 4 4
7 1646821 Plug ........................................................................................................ 2 2
8 1646820 Plug ........................................................................................................ 2 2
9 292591 Capscrew ............................................................................................... 4 4
10 296430 Washer .................................................................................................. 4 4
11 1474354 Cap ........................................................................................................ 2 2
12 192429 Bushing .................................................................................................. 2 2
13 104506 O-Ring ................................................................................................... 4 4
14 161273 Shim (0.020 in.) ..................................................................................... AR AR
15 161272 Shim (0.007 in.) ..................................................................................... AR AR
16 104264 Wear Strip .............................................................................................. 2 2
FOOTNOTES:
a Refer to Table b Replace With Larger Depending on Wear
INNER MAST
TWO STAGE LIMITED FREE-LIFT
E80XN
E100-120XN/E100XNS
KEY:
A: E80XN
B: E100-120XN/E100XNS
QTY
ITEM PART NO. DESCRIPTION A B
b. . . . . Mast Assy ................................................................................................... 1 1
1 b. . . . . Inner Mast .............................................................................................. 1 1
2 c 1399203 Load Roller ("A") (126.75/126.49) .......................................................... 2 2
2 1399204 Load Roller ("B") (127.51/127.25) .......................................................... 2 2
2 1399205 Load Roller ("C") (128.27/128.01) ......................................................... 2 2
3 1465072 Snap Ring .............................................................................................. 2 2
4 126765 Shim ....................................................................................................... 12 12
5 1387745 Chain Sheave ........................................................................................ 2 ..
5 1387744 Chain Sheave ........................................................................................ .. 2
6 126764 Double Row Bearing ......................................................................... 1 1
7 41531 Snap Ring .......................................................................................... 1 1
8 a 1389959 Bracket ................................................................................................... 2 2
9 a 1581852 Washer .................................................................................................. 2 2
10 a 1581590 Capscrew ............................................................................................... 2 2
FOOTNOTES:
a Not Used on All Applications c Replace With Larger Depending on Wear
b Refer to Table
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT (→ 10/2013)
E80XN
E100-120XN/E100XNS
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT (→ 10/2013)
FOOTNOTES:
a E100-120XN/E100XNS d Optional
b E80XN e Refer to Table
c Not Illustrated
NOTES
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT (10/2013 →)
E80XN
E100-120XN/E100XNS
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT (10/2013 →)
FOOTNOTES:
a E100-120XN/E100XNS c Optional
b E80XN d Refer to Table
NOTES
FOOTNOTES:
a Not Illustrated b Refer to Table
FOOTNOTES:
a Not Illustrated b Refer to Table
CARRIAGE
TWO STAGE LIMITED FREE-LIFT
KEY:
A: B586 Mast Series
B: B587 Mast Series
C: B587 Mast Series (Attachment)
QTY
ITEM PART NO. DESCRIPTION A B C
1401660 Carriage (42 in.) ................................................................................ 1 .. ..
1401662 Carriage (42 in.) ................................................................................ .. 1 ..
2095541 Carriage (42 in.) ................................................................................ .. .. 1
1401661 Carriage (48 in.) ................................................................................ 1 .. ..
1401663 Carriage (48 in.) ................................................................................ .. 1 ..
2095542 Carriage (48 in.) ................................................................................ .. .. 1
1 1401630 Carriage Wldmt (42 in.) ................................................................. 1 .. ..
1 1401632 Carriage Wldmt (42 in.) ................................................................. .. 1 ..
1 1653908 Carriage Wldmt (42 in.) ................................................................. .. .. 1
1 1401631 Carriage Wldmt (48 in.) ................................................................. 1 .. ..
1 1401633 Carriage Wldmt (48 in.) ................................................................. .. 1 ..
1 1653909 Carriage Wldmt (48 in.) ................................................................. .. .. 1
2 1511883 Load Roller ("B") (104.44/104.18) ................................................. 6 6 6
3 126765 Shim .............................................................................................. AR AR AR
4 1465072 Snap Ring ..................................................................................... 6 6 6
5 1399224 Spacer ........................................................................................... 2 2 2
6 1387285 Chain Anchor (E80XN) .................................................................. 2 .. ..
6 1387286 Chain Anchor (E100-120XN/E100XNS) ........................................ .. 2 2
7 327591 Pin ................................................................................................. 2 .. ..
7 339932 Pin ................................................................................................. .. 2 2
8 15222 Cotter Pin ...................................................................................... 2 2 2
9 1581896 Nut ................................................................................................. 4 4 4
10 2056815
15224 Cotter Pin ...................................................................................... 2 2 2
11 1387993
1670064 Thrust Bearing (Side Thrust Roller) .............................................. 2 2 2
12 66333 Roll Pin .......................................................................................... 2 2 2
13 1465177 Bracket (Roller) ............................................................................. 2 2 2
14 192425 Shim (0.062 in.) ............................................................................. AR AR AR
15 192424 Shim (0.030 in.) ............................................................................. AR AR AR
16 1670065 Pin ................................................................................................. 2 2 2
17 4048814
292528 Capscrew ...................................................................................... 4 4 4
18 292683 Lockwasher ................................................................................... 4 4 4
19 ..... Grease Fitting ................................................................................ 2 2 2
1516221 Kit Side Roller ............................................................................... 1 1 ..
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT
FIVE FUNCTION E80XN
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT
FIVE FUNCTION E100-120XN/E100XNS
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
b. . . . . Mast Assy .......................................................................................... 1 1 1
1 b. . . . . Hose Assy ..................................................................................... 2 2 2
2 b. . . . . Hose Assy ..................................................................................... .. 2 2
3 b. . . . . Hose Assy ..................................................................................... .. .. 1
4 b. . . . . Hose Assy ..................................................................................... .. .. 2
5 1599434 Fitting ............................................................................................ 2 4 4
7-22 See Service Manual ©2018 HYSTER COMPANY
for service procedures.
UNIT CODE A099
11/2018 NORTH AMERICA
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
6 1581743 Capscrew ...................................................................................... 4 4 4
7 1581557 Washer .......................................................................................... 4 4 4
8 1581567 Nut ................................................................................................. 4 4 4
9 1500175 Grommet ....................................................................................... 2 4 4
10 816591 Fitting ............................................................................................ 2 4 4
11 1550433 Tube Assy ..................................................................................... 1 2 2
12 1550434 Tube Assy ..................................................................................... 1 2 2
13 1550435 Plate .............................................................................................. 1 1 1
14 1599321 Plate (With Side-Shift) ................................................................... .. .. 1
15 358287 Bracket .......................................................................................... .. .. 1
16 1581563 Lockwasher ................................................................................... .. .. 2
17 1597443 Bolt ................................................................................................ .. .. 2
18 358286 Strain Relief ................................................................................... .. .. 1
19 6996681
1473887 Fitting ............................................................................................ .. .. 2
19 1495113
265731 O-Ring ...................................................................................... .. .. 1
20 358289 Hose Reel ..................................................................................... .. .. 1
20 672563 Kit-Seal ..................................................................................... .. .. 1
21 1581594 Capscrew ...................................................................................... .. .. 2
22 1581559 Washer .......................................................................................... .. .. 2
23 1618437 Plate .............................................................................................. .. .. 1
24 1581849 Nut ................................................................................................. .. .. 2
25 1360507 Clamp ............................................................................................ 2 4 4
26 1465489 Hose Clamp .................................................................................. 2 4 4
27 1502809 Hose Clamp .................................................................................. .. .. 2
28 1617658 Clamp ............................................................................................ .. .. 2
28 1360507 Clamp (With Side-Shift) ................................................................. .. .. 2
29 1477578 Spacer ........................................................................................... 1 2 2
30 2035791 Hose Clamp .................................................................................. 1 2 2
31 1581577 Capscrew ...................................................................................... 2 4 4
32 c 1495279 Hose Sheave ................................................................................. 1 2 2
32 e 4649383 Hose Sheave ................................................................................. 1 2 2
33 d 1477570 Stubshaft ....................................................................................... 1 2 2
33 f 4156025 Stubshaft ....................................................................................... 1 2 2
34 1581564 Lockwasher ................................................................................... 1 2 2
35 1581594 Capscrew ...................................................................................... 1 2 2
36 1345190 Washer .......................................................................................... 1 2 2
37 16541 Fitting ............................................................................................ .. .. 2
38 1581565 Nut ................................................................................................. 2 4 4
a 1529016 Fitting (Cap) (Hose Cap) ............................................................... 2 4 6
FOOTNOTES:
a Not Illustrated d → 9/2016
b Refer to Table e 7/2016 →
c → 7/2016 f 9/2016 →
SECTION 8
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-38
FREE-LIFT
THREE STAGE FULL FREE-LIFT (→ 10/2013) ........................................................................................ 8-26
THREE STAGE FULL FREE-LIFT (10/2013 →) ........................................................................................ 8-30
FREE-LIFT CYLINDER
THREE STAGE FULL FREE LIFT .............................................................................................................. 8-34
HEADER HOSE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-42
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-14
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-10
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-18
MAIN LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-22
OUTER MAST
THREE STAGE FULL FREE-LIFT (→ 10/2013) ........................................................................................ 8-2
THREE STAGE FULL FREE-LIFT (10/2013 →) ........................................................................................ 8-6
OUTER MAST
THREE STAGE FULL FREE-LIFT (→ 10/2013)
E80XN
E100-120XN/E100XNS
E100-120XN/E100XNS
OUTER MAST
THREE STAGE FULL FREE-LIFT (→ 10/2013)
FOOTNOTES:
a Refer to Table b Replace With Larger Depending on Wear
NOTES
OUTER MAST
THREE STAGE FULL FREE-LIFT (10/2013 →)
E80XN
E100-120XN/E100XNS
E100-120XN/E100XNS
OUTER MAST
THREE STAGE FULL FREE-LIFT (10/2013 →)
FOOTNOTES:
a Refer to Table b Replace With Larger Depending on Wear
NOTES
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
E80XN
E100-120XN/E100XNS
E100-120XN/E100XNS
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Not Illustrated c Refer to Table
b Not Used on All Applications d Replace With Larger Depending on Wear
NOTES
INNER MAST
THREE STAGE FULL FREE-LIFT
E80XN
E100-120XN/E100XNS
E100-120XN/E100XNS
FOOTNOTES:
a Refer to Table b Replace With Larger Depending on Wear
NOTES
MAIN LIFT
THREE STAGE FULL FREE-LIFT
E80XN
E100-120XN/E100XNS
E100-120XN/E100XNS
MAIN LIFT
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a E100-120XN/E100XNS c Refer to Table
b E80XN
NOTES
E100-120XN/E100XNS
E100-120XN/E100XNS
FOOTNOTES:
a Not Illustrated b Refer to Table
NOTES
FREE-LIFT
THREE STAGE FULL FREE-LIFT (→ 10/2013)
E80XN
E100-120XN/E100XNS
E100-120XN/E100XNS
FREE-LIFT
THREE STAGE FULL FREE-LIFT (→ 10/2013)
FOOTNOTES:
a E100-120XN/E100XNS c Not Illustrated
b E80XN d Refer to Table
NOTES
FREE-LIFT
THREE STAGE FULL FREE-LIFT (10/2013 →)
E80XN
E100-120XN/E100XNS
E100-120XN/E100XNS
FREE-LIFT
THREE STAGE FULL FREE-LIFT (10/2013 →)
FOOTNOTES:
a E100-120XN/E100XNS c Refer to Table
b E80XN
NOTES
FREE-LIFT CYLINDER
THREE STAGE FULL FREE LIFT
E80XN
E100-120XN/E100XNS
E100-120XN/E100XNS
FREE-LIFT CYLINDER
THREE STAGE FULL FREE LIFT
KEY:
A: E80XN
B: E100-120XN/E100XNS
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 a. . . . . Cylinder Rod .......................................................................................... 1 1
3 2036282 Gland (E80XN) ...................................................................................... 1 ..
3 1541640 Gland (E100-120XN/E100XNS) ............................................................ .. 1
4 1361302 Screw ..................................................................................................... 1 1
5 297538 Check Valve ........................................................................................... 1 1
6 297531 Washer .................................................................................................. 1 1
7 187388 Snap Ring .............................................................................................. 1 1
8 1383070 Rod Wiper .............................................................................................. 1 1
9 2033395 Seal ........................................................................................................ 1 1
10 164632 Back-Up Ring (E80XN) .......................................................................... 1 ..
10 615145 Back-Up Ring (E100-120XN/E100XNS) ................................................ .. 1
11 46629 O-Ring (E80XN) ..................................................................................... 1 ..
11 15885 O-Ring (E100-120XN/E100XNS) ........................................................... .. 1
12 636950 Wear Ring (E80XN) ............................................................................... 1 ..
12 1380982 Wear Ring (E100-120XN/E100XNS) ..................................................... .. 1
13 637162 Rod Seal (E80XN) ................................................................................. 1 ..
13 364059 Rod Seal (E100-120XN/E100XNS) ....................................................... .. 1
14 638293 Back-Up Ring (E80XN) .......................................................................... 1 ..
14 1381074 Back-Up Ring (E100-120XN/E100XNS)(E100-120XN/E100XNS) ........ .. 1
15 190580 O-Ring ................................................................................................... 1 1
16 190887 Sealing Ring .......................................................................................... 1 1
2036279 Kit-Seal (E80XN) ........................................................................................ 1 ..
2065889 Kit-Seal (E100-120XN/E100XNS) .............................................................. .. 1
FOOTNOTES:
a Refer to Table
NOTES
CARRIAGE
THREE STAGE FULL FREE-LIFT
KEY:
A: B588 Mast Series
B: B589 Mast Series
C: B589 Mast Series (Attachment)
QTY
ITEM PART NO. DESCRIPTION A B C
2108029 Carriage (42 in.) ................................................................................ 1 .. ..
2108037 Carriage (42 in.) ................................................................................ .. 1 ..
2108032 Carriage (42 in.) ................................................................................ .. .. 1
2108030 Carriage (48 in.) ................................................................................ 1 .. ..
2108038 Carriage (48 in) ................................................................................. .. 1 ..
2108033 Carriage (48 in.) ................................................................................ .. .. 1
1 1694398 Carriage Wldmt (42 in.) ................................................................. 1 .. ..
1 1692203 Carriage Wldmt (42 in.) ................................................................. .. 1 ..
1 1694595 Carriage Wldmt (42 in.) ................................................................. .. .. 1
1 1694399 Carriage Wldmt (48 in.) ................................................................. 1 .. ..
1 1692687 Carriage Wldmt (48 in.) ................................................................. .. 1 ..
1 1694596 Carriage Wldmt (48 in.) ................................................................. .. .. 1
2 1500744 Stubshaft ................................................................................... 6 6 6
3 1465177 Bracket .......................................................................................... 2 2 2
4 1387993
1670064 Thrust Bearing (Side Thrust Roller) .............................................. 2 2 2
5 1670065 Pin ................................................................................................. 2 2 2
6 292683 Lockwasher ................................................................................... 4 4 4
7 4048814
292528 Capscrew ...................................................................................... 4 4 4
8 319323 Bracket Wldmt (Guard LH) ............................................................ 1 1 1
9 319322 Bracket Wldmt (Guard RH) ........................................................... 1 1 1
10 1624590 Chain Anchor ................................................................................ 2 2 2
11 339932 Pin ................................................................................................. 2 2 2
12 15222 Cotter Pin ...................................................................................... 2 2 2
13 1465072 Snap Ring ..................................................................................... 6 6 6
14 1399224 Spacer ........................................................................................... 2 2 2
15 126765 Shim .............................................................................................. AR AR AR
16 1511883 Load Roller ("B") (104.44/104.18) ................................................. 6 6 6
17 a 317292 Spacer ........................................................................................... 4 4 4
18 a 18518 Capscrew ...................................................................................... 4 4 4
18 b 292509 Capscrew ...................................................................................... 4 4 4
19 a 15155 Lockwasher ................................................................................... 4 4 4
19 b 320157 Washer .......................................................................................... 4 4 4
20 1624589 Pin ................................................................................................. 2 2 2
21 131358 Snap Ring ..................................................................................... 2 2 2
22 66333 Roll Pin .......................................................................................... 2 2 2
23 ..... Grease Fitting ................................................................................ 2 2 2
24 192425 Shim (0.062 in.) ............................................................................. AR AR AR
25 192424 Shim (0.030 in.) ............................................................................. AR AR AR
1516221 Kit Side Roller ............................................................................... 1 1 ..
FOOTNOTES:
a → 11/2015 b 11/2015 →
NOTES
HEADER HOSE
THREE STAGE FULL FREE-LIFT
FIVE FUNCTION E80XN
HEADER HOSE
THREE STAGE FULL FREE-LIFT
FIVE FUNCTION E100-120XN/E100XNS
HEADER HOSE
THREE STAGE FULL FREE-LIFT
THREE FUNCTION E100-120XN/E100XNS
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
b. . . . . Mast Assy .......................................................................................... 1 1 1
1 b. . . . . Hose Assy ..................................................................................... 2 2 2
2 b. . . . . Hose Assy ..................................................................................... .. 2 2
3 1581577 Capscrew ...................................................................................... 4 8 8
4 1581565 Nut ................................................................................................. 4 8 8
5 1387523 Bracket Wldmt ............................................................................... 1 2 2
6 1495279 Hose Sheave ................................................................................. 1 2 2
6 332057 Bushing ..................................................................................... 1 2 2
7 1581560 Washer .......................................................................................... 2 4 4
8 58902 Snap Ring ..................................................................................... 2 4 4
9 2035791 Hose Clamp .................................................................................. 4 8 8
10 1581741 Capscrew ...................................................................................... 4 8 8
11 1569979 Clamp ............................................................................................ 2 2 2
12 1465489 Hose Clamp .................................................................................. 2 4 4
13 1387327 Bracket .......................................................................................... 1 1 1
13 4233245 Bracket (Alternate Part) ................................................................. 1 1 1
14 4166624
1581556 Washer .......................................................................................... 2 4 4
15 1581562 Lockwasher ................................................................................... 2 4 4
16 1581579 Capscrew ...................................................................................... 2 4 4
17 1541242 Bracket Wldmt (RH) ...................................................................... 1 1 1
18 302472 Roll Pin .......................................................................................... 1 2 2
19 1528580 Fitting ............................................................................................ 1 2 2
20 1550425 Fitting ............................................................................................ 1 2 2
21 1581587 Capscrew ...................................................................................... 2 4 4
22 1581563 Lockwasher ................................................................................... 2 4 4
23 4155140 Bracket .......................................................................................... 1 1 1
24 1502809 Hose Clamp .................................................................................. 1 2 2
25 1399243 Clamp ............................................................................................ 1 2 2
26 1581586 Capscrew ...................................................................................... 1 1 1
27 1581567 Nut ................................................................................................. 1 1 1
28 1389854 Bracket .......................................................................................... .. 1 1
28 4233246 Bracket (Alternate Part) ................................................................. .. 1 1
HEADER HOSE
THREE STAGE FULL FREE-LIFT
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
29 1617658 Clamp ............................................................................................ .. 2 2
30 1541243 Bracket Wldmt (LH) ....................................................................... .. 1 1
31 2077914 Hose Assy ..................................................................................... .. .. 1
32 b. . . . . Hose Assy ..................................................................................... .. .. 2
33 358286 Strain Relief ................................................................................... .. .. 1
34 358287 Bracket .......................................................................................... .. .. 1
35 1597443 Bolt (With Side-Shift) ..................................................................... .. .. 2
35 1597443 Bolt (Without Side-Shift) ................................................................ .. .. 3
36 1581563 Lockwasher (With Side-Shift) ........................................................ .. .. 2
36 1581563 Lockwasher (Without Side-Shift) ................................................... .. .. 3
37 358289 Hose Reel ..................................................................................... .. .. 1
37 672563 Kit-Seal ..................................................................................... .. .. 1
38 6996681
1473887 Fitting ............................................................................................ .. .. 2
38 1495113
265731 O-Ring ...................................................................................... .. .. 1
39 1618437 Plate .............................................................................................. .. .. 1
40 1581594 Capscrew ...................................................................................... .. .. 2
41 1581559 Washer .......................................................................................... .. .. 2
42 1705595 Bracket (Without Side-Shift) .......................................................... .. .. 1
42 136692 Nut (Without Side-Shift) ................................................................ .. .. 1
42 1599322 Plate (With Side-Shift) ................................................................... .. .. 1
43 1502809 Hose Clamp .................................................................................. .. .. 2
44 1569979 Clamp (With Side-Shift) ................................................................. .. .. 2
44 1617658 Clamp (Without Side-Shift) ............................................................ .. .. 2
45 1581590 Capscrew ...................................................................................... 1 2 2
46 16541 Fitting ............................................................................................ .. .. 2
47 1581849 Nut ................................................................................................. .. .. 2
48 d 1495279 Hose Sheave ................................................................................. 1 2 2
48 e 4649383 Hose Sheave ................................................................................. 1 2 2
48 332057 Bushing ..................................................................................... 1 2 2
a 1529016 Fitting (Cap) .................................................................................. 2 4 6
a c 129563 Strap Clamp .................................................................................. 1 2 2
FOOTNOTES:
a Not Illustrated d → 9/2016
b Refer to Table e 9/2016 →
c Strap hoses to prevent rubbing on chain by
attaching to item 17 and 30
SECTION 9
MAST-TWO STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-28
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-18
HEADER HOSE
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-22
INNER MAST AND FREE-LIFT
TWO STAGE FULL FREE-LIFT (→ 10/2013) ............................................................................................ 9-6
TWO STAGE FULL FREE-LIFT (10/2013 →) ............................................................................................ 9-10
MAIN LIFT CYLINDER
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-14
OUTER MAST AND MAIN LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-2
B591
FOOTNOTES:
a Refer to Table c With VPDP and Accumulator
b Replace With Larger Depending on Wear
NOTES
B591
FOOTNOTES:
a Not Illustrated b Refer to Table
NOTES
B591
FOOTNOTES:
a Refer to Table
NOTES
RIGHT HAND
LEFT HAND
KEY:
A: B590 Mast Series
B: B591 Mast Series
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ............................................................................. 1 1
2 190887 Sealing Ring .......................................................................................... 1 1
3 295649 Screw ..................................................................................................... 1 1
4 1379063 Piston Ring ............................................................................................ .. 1
5 1381055 Piston (E80XN) ...................................................................................... 1 ..
5 1381056 Piston (E100-120XN/E100XNS) ............................................................ .. 1
6 186061 Lubricant ................................................................................................ AR AR
7 2038675 Wear Ring .............................................................................................. 1 1
8 a. . . . . Cylinder Rod .......................................................................................... 1 1
9 1310370 Rod Wiper (E80XN) ............................................................................... 1 ..
9 1310371 Rod Wiper (E100-120XN/E100XNS) ..................................................... .. 1
10 1381084 Rod Seal (E80XN) ................................................................................. 1 ..
10 1381086 Rod Seal (E100-120XN/E100XNS) ....................................................... .. 1
11 2033295 Gland (E80XN) ...................................................................................... 1 ..
11 2033296 Gland (E100-120XN/E100XNS) ............................................................ .. 1
12 198518 O-Ring ................................................................................................... 1 1
13 166659 Back-Up Ring ......................................................................................... 1 1
14 357626 Spacer ................................................................................................... 1 ..
2038676 Kit-Seal (E80XN) ........................................................................................ 1 ..
2104947 Kit-Seal (E100-120XN/E100XNS) .............................................................. .. 1
FOOTNOTES:
a Refer to Table
NOTES
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT
B590
B591
KEY:
A: B590 Mast Series
B: B591 Mast Series
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ............................................................................................. 1 1
1 a. . . . . Tube Wldmt-Cylinder ................................................................................. 1 1
2 a. . . . . Cylinder Rod .............................................................................................. 1 1
3 2036282 Gland (E80XN) ...................................................................................... 1 ..
3 1541640 Gland (E100-120XN/E100XNS) ............................................................ .. 1
4 1361302 Screw ..................................................................................................... 1 1
5 297538 Check Valve ........................................................................................... 1 1
6 297531 Washer .................................................................................................. 1 1
7 187388 Snap Ring .............................................................................................. 1 1
8 1383070 Rod Wiper .............................................................................................. 1 1
9 2033395 Seal ........................................................................................................ 1 1
10 164632 Back-Up Ring (E80XN) .......................................................................... 1 ..
10 615145 Back-Up Ring (E100-120XN/E100XNS) ................................................ .. 1
11 46629 O-Ring (E80XN) ..................................................................................... 1 ..
11 15885 O-Ring (E100-120XN/E100XNS) ........................................................... .. 1
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT
KEY:
A: B590 Mast Series
B: B591 Mast Series
QTY
ITEM PART NO. DESCRIPTION A B
12 636950 Wear Ring (E80XN) ............................................................................... 1 ..
12 1380982 Wear Ring (E100-120XN/E100XNS) ..................................................... .. 1
13 637162 Rod Seal (E80XN) ................................................................................. 1 ..
13 364059 Rod Seal (E100-120XN/E100XNS) ....................................................... .. 1
14 638293 Back-Up Ring (E80XN) .......................................................................... 1 ..
14 1381074 Back-Up Ring (E100-120XN/E100XNS) ................................................ .. 1
15 190580 O-Ring ................................................................................................... 1 1
16 190887 Sealing Ring .......................................................................................... 1 1
2036279 Kit-Seal (E80XN) ........................................................................................ 1 ..
2065889 Kit-Seal (E100-120XN/E100XNS) .............................................................. .. 1
FOOTNOTES:
a Refer to Table
NOTES
HEADER HOSE
TWO STAGE FULL FREE-LIFT
FIVE FUNCTION E80XN
HEADER HOSE
TWO STAGE FULL FREE-LIFT
THREE FUNCTION E80XN
HEADER HOSE
TWO STAGE FULL FREE-LIFT
FOUR FUNCTION E100-120XN/E100XNS
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
a. . . . . Mast Assy .......................................................................................... 1 1 1
1 a. . . . . Hose Assy ..................................................................................... 2 2 2
2 a. . . . . Hose Assy ..................................................................................... 2 2 2
3 a. . . . . Channel ......................................................................................... 1 1 1
4 a. . . . . Channel ......................................................................................... 1 1 1
5 a. . . . . Hose Assy ..................................................................................... 2 2 2
6 a. . . . . Hose Assy ..................................................................................... .. 1 2
7 a. . . . . Hose Assy ..................................................................................... .. 2 2
HEADER HOSE
TWO STAGE FULL FREE-LIFT
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
8 a. . . . . Hose Assy ..................................................................................... .. .. 2
9 1360507 Clamp ............................................................................................ 2 2 2
10 1654323 Capscrew ...................................................................................... 2 2 2
11 1541242 Bracket Wldmt ............................................................................... 1 1 1
12 1581560 Washer .......................................................................................... 1 1 1
13 b 1495279 Hose Sheave ................................................................................. 1 1 1
13 c 4649383 Hose Sheave ................................................................................. 1 1 1
13 332057 Bushing ..................................................................................... 1 1 1
14 58902 Snap Ring ..................................................................................... 1 1 1
15 302472 Roll Pin .......................................................................................... 1 1 1
16 2079377 Tube Assy ..................................................................................... 1 1 1
17 2079376 Tube Assy ..................................................................................... 1 1 1
18 1360529 Clamp ............................................................................................ 1 1 1
19 2035791 Hose Clamp .................................................................................. 2 2 2
20 1581742 Capscrew ...................................................................................... 2 2 2
21 1502809 Hose Clamp .................................................................................. 1 1 1
22 1399323 Pad ................................................................................................ 2 2 2
23 1397682 Clamp ............................................................................................ 2 2 2
24 4166624
1581556 Washer .......................................................................................... 4 4 4
25 1581562 Lockwasher ................................................................................... 2 2 2
26 1581582 Capscrew ...................................................................................... 2 2 2
27 1581835 Capscrew ...................................................................................... 1 1 1
28 1581739 Nut ................................................................................................. 1 1 1
29 358286 Strain Relief ................................................................................... .. 1 2
30 358287 Bracket .......................................................................................... .. 1 2
31 1597443 Bolt ................................................................................................ .. 2 4
32 1581563 Lockwasher ................................................................................... .. 2 4
33 358289 Hose Reel ..................................................................................... .. 1 1
33 672563 Kit-Seal ..................................................................................... .. 1 1
34 16541 Fitting ............................................................................................ .. 2 4
34 16484 O-Ring ...................................................................................... .. 1 1
35 1618437 Plate .............................................................................................. .. 1 2
36 1581594 Capscrew ...................................................................................... .. 2 4
37 1581559 Washer .......................................................................................... .. 2 4
38 1599321 Plate (With Side-Shift) ................................................................... .. .. 1
39 1502809 Hose Clamp .................................................................................. .. 2 4
40 1360507 Clamp (With Side-Shift) ................................................................. .. 2 4
40 1617658 Clamp (Without Side-Shift) ............................................................ .. .. 2
41 378044 Hose Reel ..................................................................................... .. .. 1
41 672563 Kit-Seal ..................................................................................... .. .. 1
42 1581849 Nut ................................................................................................. .. 2 4
43 1528580 Fitting ............................................................................................ 1 1 1
44 1529016 Fitting (Cap) (Mast Removal) ........................................................ 2 4 6
HEADER HOSE
TWO STAGE FULL FREE-LIFT
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
45 1581565 Nut ................................................................................................. 2 2 2
46 6996681
1473887 Fitting ............................................................................................ .. 2 4
47 1581590 Capscrew ...................................................................................... 1 1 1
48 2091910 Tube Assy ..................................................................................... .. 1 1
49 2091911 Tube Assy ..................................................................................... .. 1 1
50 ..... Bracket .......................................................................................... .. 1 1
51 1550425 Fitting ............................................................................................ 1 1 1
FOOTNOTES:
a Refer to Table c 7/2016 →
b → 7/2016
CARRIAGE
TWO STAGE FULL FREE-LIFT
KEY:
A: B590 Mast Series
B: B591 Mast Series
C: B591 Mast Series (Attachment)
QTY
ITEM PART NO. DESCRIPTION A B C
2108024 Carriage (42 in) ................................................................................. 1 .. ..
2108034 Carriage (42 in.) ................................................................................ .. 1 ..
2108026 Carriage (42 in.) ................................................................................ .. .. 1
2108025 Carriage (48 in.) ................................................................................ 1 .. ..
2108035 Carriage (48 in.) ................................................................................ .. 1 ..
2108027 Carriage (48 in.) ................................................................................ .. .. 1
1 1695566 Carriage Wldmt (42 in.) ................................................................. 1 .. ..
1 1692911 Carriage Wldmt (42 in.) ................................................................. .. 1 ..
1 1695160 Carriage Wldmt (42 in.) ................................................................. .. .. 1
1 1695567 Carriage Wldmt (48 in) .................................................................. 1 .. ..
1 1692912 Carriage Wldmt (48 in.) ................................................................. .. 1 ..
1 1695161 Carriage Wldmt (48 in.) ................................................................. .. .. 1
2 1500744 Stubshaft ................................................................................... 6 6 6
3 1465177 Bracket .......................................................................................... 2 2 2
4 1387993
1670064 Thrust Bearing (Side Thrust Roller) .............................................. 2 2 2
5 1670065 Pin ................................................................................................. 2 2 2
6 292683 Lockwasher ................................................................................... 4 4 4
7 4048814
292528 Capscrew ...................................................................................... 4 4 4
8 319323 Bracket Wldmt (Guard LH) ............................................................ 1 1 1
9 319322 Bracket Wldmt (Guard RH) ........................................................... 1 1 1
10 1624590 Chain Anchor ................................................................................ 2 2 2
11 339932 Pin ................................................................................................. 2 2 2
12 15222 Cotter Pin ...................................................................................... 2 2 2
13 1465072 Snap Ring ..................................................................................... 6 6 6
14 1399224 Spacer ........................................................................................... 2 2 2
15 126765 Shim .............................................................................................. 24 24 24
16 1511883 Load Roller ("B") (104.44/104.18) ................................................. 6 6 6
17 a 317292 Spacer ........................................................................................... 4 4 4
18 a 18518 Capscrew ...................................................................................... 4 4 4
18 b 292509 Capscrew ...................................................................................... 4 4 4
19 a 15155 Lockwasher ................................................................................... 4 4 4
19 b 320157 Washer .......................................................................................... 4 4 4
20 1624589 Pin ................................................................................................. 2 2 2
21 131358 Snap Ring ..................................................................................... 2 2 2
22 66333 Roll Pin .......................................................................................... 2 2 2
23 ..... Grease Fitting ................................................................................ 2 2 2
24 192425 Shim (0.062 in.) ............................................................................. AR AR AR
25 192424 Shim (0.030 in.) ............................................................................. AR AR AR
1516221 Kit Side Roller ............................................................................... 1 1 ..
FOOTNOTES:
a → 11/2015 b 11/2015 →
10 OPTIONS
UNIT CODE A099
11/2018 NORTH AMERICA
SECTION 10
OPTIONS
DESCRIPTION PAGE
NOTES
ACCUMULATOR
ITEM PART NO. DESCRIPTION QTY
1 1465897 Accumulator ........................................................................................................ 1
2 1609864 Spacer ................................................................................................................ 2
3 4031653 Strap Clamp ........................................................................................................ 2
4 2091868 Hose Assy ........................................................................................................... 1
5 1487096 Fitting .................................................................................................................. 1
5 1495114
252729 O-Ring ............................................................................................................ 3
FOOTNOTES:
a When DC-DC Converter is Equipped b Without DC-DC Converter Equipped
NOTES
FOOTNOTES:
a Not Illustrated, Located between item 2 and b Not Illustrated, Located on Top 2 Rollers
carriage
FOOTNOTES:
a Not Illustrated, Located Between Item 2 and b Not Illustrated, Located with top two load rollers.
carriage
NOTES
FOOTNOTES:
a Three Stage Full Free-Lift b Two Stage Full Free-Lift
FOOTNOTES:
a Used with Attachment Carriage b Used with ISS Carriage
FOOTNOTES:
a Use with Attachment Carriage b Use With ISS Carriage
FOOTNOTES:
a Use with ISS Carriage b Used with Attachment Carriage
NOTES
FOOTNOTES:
a Used with Attachment Carriage b Used with ISS Carriage
FOOTNOTES:
a Used with Attachment Carriage b Used with ISS Carriage
FOOTNOTES:
a Used with Attachment Carriage b Used with ISS Carriage
KEY:
A: B590, Three Function
B: B590, Four Function
C: B591, Three Function
D: B591, Four Function
QTY
ITEM PART NO. DESCRIPTION A B C D
1 2091911 Tube Assy ................................................................................. .. 1 .. 1
2 816591 Fitting ........................................................................................ 2 4 2 4
3 1705597 Bracket (LH) .............................................................................. .. 1 .. 1
4 1581563 Lockwasher ............................................................................... 2 4 2 4
5 1597443 Bolt ............................................................................................ 2 4 2 4
6 2091910 Tube Assy ................................................................................. .. 1 .. 1
7 1705595 Bracket (RH) ............................................................................. 1 1 1 1
8 2089557 Tube Assy ................................................................................. 1 1 .. ..
8 2089911 Tube Assy ................................................................................. .. .. 1 1
8 a 2089563 Tube Assy ................................................................................. .. .. 1 1
9 2089556 Tube Assy ................................................................................. 1 1 .. ..
9 2089910 Tube Assy ................................................................................. .. .. 1 1
9 a 2089562 Tube Assy ................................................................................. .. .. 1 1
FOOTNOTES:
a Used with Attachment Carriage
NOTES
FOOTNOTES:
a Used with Attachment Carriage
FOOTNOTES:
a Used with Attachment Carriage b Used with ISS Carriage
SECTION 11
FIELD CONVERSION KITS
DESCRIPTION PAGE
CONVERSION KIT
HYDRAULICS
FOOTNOTES:
a Kit requires software that must be Dealer installed.
b Requires Software to be activated
CONVERSION KIT
MISCELLANEOUS
CONVERSION KIT
BATTERY ROLLERS
FOOTNOTES:
a Kit requires software that must be Dealer installed.
REPAIR KITS
12 NUMERICAL INDEX
UNIT CODE A099
11/2018 NORTH AMERICA
SECTION 12
NUMERICAL INDEX
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM