PDR Manual h1.6-1.8ft
PDR Manual h1.6-1.8ft
PDR Manual h1.6-1.8ft
MANUAL
FORTENS
H1.6-1.8FT, H2.0FTS
(F001)
CUSTOMER EDITION
SECTIONS
1 FRAME
2 ENGINES
3 FUEL SYSTEM
4 ELECTRICAL SYSTEM
5 TRANSMISSION
6 DRIVE AXLE
7 STEERING SYSTEM
8 BRAKE SYSTEM
9 HYDRAULIC SYSTEM
13 OPTIONS
14 NUMERICAL INDEX
This Parts Manual is divided into 14 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 F001
03/2007 EUROPE
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCUMULATOR .............................................................................................................................................. 13-10
AIR CLEANER FILTER ASSEMBLY
LPG AND DIESEL .......................................................................................................................................... 3-12
AIR CLEANER SYSTEM
DIESEL
PENDING PER ECN 10402532⇒ ................................................................................................................ 3-8
⇒PENDING PER ECN 10402532 ................................................................................................................ 3-6
MAZDA 2..0L
PENDING PER ECN 104522⇒ .................................................................................................................... 3-4
MAZDA 2.0L
⇒PENDING PER ECN 104522 .................................................................................................................... 3-2
ALTERNATOR AND MOUNTING
YANMAR 2.6L DIESEL ................................................................................................................................... 4-39
AUXILARY TUBE EXTENSIONS
TWO STAGE FULL FREE-LIFT AND THREE STAGE FULL FREE-LIFT..................................................... 13-22
TWO STAGE LIMITED FREE-LIFT............................................................................................................... 13-20
AUXILIARY ONE SECTION
ELECTRONIC CONTROL
THREE AND FOUR FUNCTION................................................................................................................. 9-34
AUXILIARY SECTIONS, ONE AND TWO
MANUAL CONTROL VALVE
THREE AND FOUR FUNCTION................................................................................................................. 9-22
AUXILIARY TWO SECTION
ELECTRONIC CONTROL
FOUR FUNCTION....................................................................................................................................... 9-36
B
BACK-UP ALARM .............................................................................................................................................. 13-5
BRAKE ASSEMBLY ............................................................................................................................................. 8-6
BRAKE LINKAGE
DUAL PEDAL.................................................................................................................................................... 8-4
SINGLE PEDAL ................................................................................................................................................ 8-2
C
CAB
WINDOWS AND WINDOW WIPER SYSTEM ................................................................................................ 1-62
WIRING AND ATTACHING PARTS................................................................................................................. 1-60
CAB AND ATTACHING PARTS
WITH PVC DOORS ........................................................................................................................................ 1-56
WITH STEEL DOORS .................................................................................................................................... 1-48
CAB ASSEMBLY
WITH STEEL DOORS .................................................................................................................................... 1-46
CAB DOORS
PVC................................................................................................................................................................. 1-58
CAMSHAFT AND DRIVE GEAR
YANMAR 2.6L DIESEL ................................................................................................................................... 2-64
CAMSHAFT AND VALVES
LPG
MAZDA 2.0L ................................................................................................................................................ 2-30
CARBURETOR
DESCRIPTION PAGE
C (continued)
LPG
MAZDA 2.0L................................................................................................................................................ 2-34
CARRIAGE
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-20
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-16
TWO STAGE LIMITED FREE-LIFT............................................................................................................... 10-12
CONTROL LEVER LABELS............................................................................................................................... 1-32
CONTROL VALVE
TRANSMISSION............................................................................................................................................. 5-34
CONTROL VALVE ASSEMBLY
ELECTRONIC CONTROL
THREE AND FOUR FUNCTION................................................................................................................. 9-25
MANUAL CONTROL
THREE AND FOUR FUNCTION................................................................................................................. 9-18
COOLING SYSTEM
MAZDA 2.0L
LPG
PENDING PER ECN 10402518⇒........................................................................................................... 2-10
⇒PENDING PER ECN 10402518............................................................................................................. 2-8
YANMAR 2.6L DIESEL
PENDING PER ECN 10402518⇒ .............................................................................................................. 2-46
⇒PENDING PER ECN 10402518 .............................................................................................................. 2-44
COUNTERWEIGHT
D/B 04/2007⇒ ................................................................................................................................................ 1-12
⇒D/B 04/2007 ................................................................................................................................................ 1-10
COUNTERWEIGHT EXHAUST
MAZDA 2.0L
WITH CATALYTIC CONVERTER ................................................................................................................ 2-12
COWL ELECTRICAL.......................................................................................................................................... 4-18
COWL MOUNTING .............................................................................................................................................. 1-8
CRANKSHAFT AND PISTONS
LPG
MAZDA 2.0L................................................................................................................................................ 2-40
YANMAR 2.6L DIESEL ................................................................................................................................... 2-66
CYLINDER BLOCK
LPG
MAZDA 2.0L................................................................................................................................................ 2-32
YANMAR 2.6L DIESEL ................................................................................................................................... 2-68
CYLINDER HEAD
YANMAR 2.6L DIESEL ................................................................................................................................... 2-62
CYLINDER HEAD AND COVER
LPG
MAZDA 2.0L................................................................................................................................................ 2-28
D
DELAY VALVE
MAZDA 2.0L
LPG
S/N F001B02574D⇒ ............................................................................................................................... 2-42
DESCRIPTION PAGE
D (continued)
DISTRIBUTER
MAZDA 2.0L ................................................................................................................................................... 4-38
DRIVE AXLE ........................................................................................................................................................ 6-2
DRIVE TIRES AND WHEELS .............................................................................................................................. 6-5
PNEUMATIC RADIAL ....................................................................................................................................... 6-6
E
ELECTRICAL SYSTEM
CHASSIS .......................................................................................................................................................... 4-4
ELECTRO HYDRAULIC POPPET VALVE
ELECTRONIC CONTROL
HOIST AND LOWER................................................................................................................................... 9-32
ELECTRONIC CONTROL LEVERS................................................................................................................... 4-26
ELECTRONIC LEVER LABELS
AUXILIARY DUAL FUNCTION ....................................................................................................................... 1-36
AUXILIARY SINGLE FUNCTION.................................................................................................................... 1-34
ELECTRONIC THROTTLE LINKAGE
YANMAR DIESEL ........................................................................................................................................... 3-44
ENGINE ELECTRICAL COMPONENTS
MAZDA 2.0L ..................................................................................................................................................... 4-8
ENGINE ELECTRICAL SYSTEM
MAZDA 2.0L
LPG ............................................................................................................................................................. 4-10
YANMAR 2.6L DIESEL ................................................................................................................................... 4-14
ENGINE FUEL SYSTEM AND EMMISSION CONTROL
MAZDA 2.0L ................................................................................................................................................... 2-26
ENGINE MOUNTING ........................................................................................................................................... 2-4
EXHAUST
WITH PURIFIER
YANMAR 2.6L DIESEL................................................................................................................................ 2-50
WITHOUT PURIFIER
YANMAR 2.6L DIESEL................................................................................................................................ 2-52
EXHAUST SYSTEM
MAZDA 2.0L
WITHOUT CATALYTIC CONVERTER
S/N F001B02723D⇒ ............................................................................................................................... 2-18
F
FAN ASSEMBLY................................................................................................................................................... 2-6
FENDER EXTENSIONS AND MUD GUARDS
WITH WIDE TREAD ......................................................................................................................................... 1-6
FLOORPLATES AND COVERS ........................................................................................................................... 1-4
FLYWHEEL AND HOUSING
MAZDA 2.0L
⇒S/N F001B02042D................................................................................................................................... 2-20
S/N F001B02043D⇒................................................................................................................................... 2-22
YANMAR 2.6L DIESEL ................................................................................................................................... 2-56
FORKS ............................................................................................................................................................... 1-42
FORWARD CLUTCH
DESCRIPTION PAGE
F (continued)
INPUT
⇒PENDING PER ECN 10402574 .............................................................................................................. 5-20
FORWARD CLUTCH (INPUT)
PENDING PER ECN 10402574⇒ .................................................................................................................. 5-30
FREE LIFT CYLINDER
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-14
FREE-LIFT
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-16
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-12
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-18
FUEL FILTER
YANMAR 2.6L DIESEL ................................................................................................................................... 3-36
FUEL INJECTION
YANMAR 2.6L DIESEL ................................................................................................................................... 3-38
FUEL SYSTEM
DIESEL ........................................................................................................................................................... 3-34
MAZDA 2.0L ................................................................................................................................................... 3-14
FULL SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS ....................................................................................... 1-20
WITH LIMITED BACK TILT
D/B 09/2006⇒............................................................................................................................................. 1-24
FULL SUSPENSION SWIVEL SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS ....................................................................................... 1-22
WITH LIMITED BACK TILT
D/B 09/2006⇒............................................................................................................................................. 1-26
G
GEAR HOUSING
YANMAR 2.6L DIESEL ................................................................................................................................... 2-58
GEAR PUMP
MAZDA 2.0L ..................................................................................................................................................... 9-4
YANMAR DIESEL ............................................................................................................................................. 9-5
H
HAND LEVERS
FOUR FUNCTION
WITH DETENTED LEVERS........................................................................................................................ 9-16
WITHOUT DETENTED LEVERS ................................................................................................................ 9-14
THREE FUNCTION
WITH DETENTED LEVERS........................................................................................................................ 9-12
WITHOUT DETENTED LEVERS ................................................................................................................ 9-10
HEADER HOSE
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-22
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-18
HEADER HOSES
TWO STAGE LIMITED FREE-LIFT............................................................................................................... 10-14
HOOD................................................................................................................................................................... 1-2
HYDRAULIC FILTER ............................................................................................................................................ 9-6
DESCRIPTION PAGE
H (continued)
I
IMPACT SENSOR ................................................................................................................................................ 4-6
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-6
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-4
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 10-4
INSTRUMENT CLUSTER .................................................................................................................................. 4-22
INTAKE AND EXHAUST MANIFOLDS
MAZDA 2.0L ................................................................................................................................................... 2-24
YANMAR 2.6L DIESEL ................................................................................................................................... 2-54
INTEGRAL SIDE-SHIFT ASSEMBLY
TWO AND THREE STAGE FULL FREE-LIFT .............................................................................................. 13-14
TWO STAGE LIMITED FREE-LIFT............................................................................................................... 13-12
INTEGRAL SIDE-SHIFT CYLINDER ............................................................................................................... 13-16
INTEGRAL SIDE-SHIFT HYDRAULIC HOSES
TWO AND THREE STAGE FULL FREE-LIFT .............................................................................................. 13-18
TWO STAGE LIMITED FREE-LIFT............................................................................................................... 13-17
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-4
J
JOYSTICK .......................................................................................................................................................... 4-24
JOYSTICK LABELS............................................................................................................................................ 1-38
WITH RETURN TO SET TILT......................................................................................................................... 1-40
L
LABELS
EXTERIOR...................................................................................................................................................... 1-28
INTERIOR....................................................................................................................................................... 1-30
LOAD BACKREST EXTENSION........................................................................................................................ 1-44
LOAD WEIGH ELECTRICAL ............................................................................................................................. 4-36
LPG TANK BRACKET
SWING OUT
⇒D/B 09/2006............................................................................................................................................. 3-18
SWING OUT, WITH FABRIC STRAP
D/B 09/2006⇒ PENDING PER ECN 104640 ............................................................................................. 3-20
PENDING PER ECN 104640⇒ .................................................................................................................. 3-22
SWING OUT/DROP DOWN
⇒D/B 09/2006............................................................................................................................................. 3-24
D/B 09/2006⇒ PENDING PER ECN 104640 ............................................................................................. 3-28
SWING OUT/DROP DOWN WITH FABRIC STRAP
PENDING PER ECN 104640⇒ .................................................................................................................. 3-32
LUBRICATION SYSTEM
YANMAR 2.6L DIESEL ................................................................................................................................... 2-72
DESCRIPTION PAGE
M
MAIN LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-8
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-6
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 10-6
MAIN LIFT CYLINDER
LEFT HAND
THREE STAGE FULL FREE-LIFT ............................................................................................................ 12-14
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-10
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 10-10
RIGHT HAND
THREE STAGE FULL FREE-LIFT ............................................................................................................ 12-12
TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-8
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 10-8
MAST ELECTRICAL
TILT SENSOR................................................................................................................................................. 4-34
MAST INSTALLATION........................................................................................................................................ 9-40
MIRRORS........................................................................................................................................................... 13-7
MONOTROL PEDAL .......................................................................................................................................... 3-46
N
NON SUSPENSION SEAT
WITHOUT ELECTRONIC CONTROLS .......................................................................................................... 1-16
O
OIL PAN
YANMAR 2.6L DIESEL ................................................................................................................................... 2-60
OIL PUMP AND FILTER
LPG (MAZDA 2.0L) ......................................................................................................................................... 2-38
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-2
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-2
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 10-2
OUTLET SECTION
ELECTRONIC CONTROL;
THREE AND FOUR FUNCTION................................................................................................................. 9-38
MANUAL CONTROL VALVE
THREE AND FOUR FUNCTION................................................................................................................. 9-24
OVERHEAD EXHAUST
MAZDA 2.0L
WITH CATALYTIC CONVERTER ................................................................................................................ 2-14
MAZDA 2.0L LPG
WITHOUT CATALYTIC CONVERTER
⇒S/N F001B02723D ............................................................................................................................... 2-16
WITHOUT CATALYTIC CONVERTER
YANMAR 2.6L ............................................................................................................................................. 2-48
OVERHEAD GUARD.......................................................................................................................................... 1-14
DESCRIPTION PAGE
P
PARK BRAKE ....................................................................................................................................................... 8-8
POWER DISTRIBUTION MODULE
PENDING PER ECN 10419489⇒ .................................................................................................................. 4-21
⇒PENDING PER ECN 10419489 .................................................................................................................. 4-20
PRE-CLEANER AND MOUNT ........................................................................................................................... 3-10
R
REVERSE CLUTCH
COUNTER
⇒PENDING PER ECN 10402574 .............................................................................................................. 5-22
REVERSE CLUTCH (COUNTER)
PENDING PER ECN 10402574⇒ .................................................................................................................. 5-32
S
SEMI SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS ....................................................................................... 1-18
STEEL DOOR
LEFT HAND .................................................................................................................................................... 1-54
STEEL DOOR AND HEATER ASSEMBLY
RIGHT HAND.................................................................................................................................................. 1-50
STEER TIRES AND WHEELS ........................................................................................................................... 7-11
STEERING AXLE ................................................................................................................................................. 7-8
STEERING COLUMN ASSEMBLY....................................................................................................................... 7-4
STEERING CONTROL UNIT ............................................................................................................................... 7-6
STEERING CYLINDER ...................................................................................................................................... 7-10
STEERING SYSTEM ........................................................................................................................................... 7-2
STROBE LIGHT
LED
PENDING PER ECN 10298201⇒ .............................................................................................................. 13-4
⇒PENDING PER ECN 10298201 .................................................................................................................. 13-2
T
THROTTLE CABLE LINKAGE
YANMAR DIESEL ........................................................................................................................................... 3-42
THROTTLE LINKAGE
MAZDA 2.0L ................................................................................................................................................... 3-40
TILT AND AUXILIARY HOSES ............................................................................................................................. 9-8
TILT CYLINDERS
LEFT HAND .................................................................................................................................................... 9-44
RIGHT HAND.................................................................................................................................................. 9-42
TILT SECTION
ELECTRONIC CONTROL
THREE AND FOUR FUNCTION................................................................................................................. 9-30
TIMING GEAR COVER AND OIL PAN
MAZDA 2.0L
LPG ............................................................................................................................................................. 2-36
TORQUE CONVERTER....................................................................................................................................... 5-3
TRANSMISSION
SINGLE SPEED
SHEET 1 OF 2
DESCRIPTION PAGE
T (continued)
V
VALVE ASSEMBLY, LIFT AND LOWER
ELECTRONIC CONTROL VALVE
THREE AND FOUR FUNCTION................................................................................................................. 9-28
VALVE ASSEMBLY, LIFT AND TILT
MANUAL CONTROL VALVE
THREE AND FOUR FUNCTION................................................................................................................. 9-20
W
WATER PUMP
YANMAR 2.6L DIESEL ................................................................................................................................... 2-70
WEATHER PROTECTION.................................................................................................................................. 1-64
WIRE HARNESS
BACK-UP ALARM........................................................................................................................................... 13-8
CHASSIS
MAZDA 2.0L
D/B 08/2006⇒ ......................................................................................................................................... 4-46
⇒D/B 08/2006 ......................................................................................................................................... 4-40
YANMAR 2.6L DIESEL
D/B 08/2006⇒ ......................................................................................................................................... 4-58
YANMAR DIESEL 2.6L
⇒D/B 08/2006 ......................................................................................................................................... 4-52
COWL WITH FORWARD/REVERSE LEVER
WITHOUT RETURN TO SET TILT.............................................................................................................. 4-68
COWL WITH MONOTROL PEDAL
WITH RETURN TO SET TILT ..................................................................................................................... 4-64
DIESEL ENGINE
YANMAR 2.6L
D/B 08/2006⇒ ......................................................................................................................................... 4-78
⇒D/B 08/2006 ......................................................................................................................................... 4-76
ELECTRONIC CONTROL VALVE
3 FUNCTION............................................................................................................................................... 4-80
4 FUNCTION............................................................................................................................................... 4-82
LIGHTS
PENDING PER ECN 10419449⇒ .............................................................................................................. 4-90
⇒PENDING PER ECN 10419449 .............................................................................................................. 4-88
DESCRIPTION PAGE
W (continued)
LPG ENGINE
MAZDA 2.0L
D/B 08/2006⇒ ......................................................................................................................................... 4-74
⇒D/B 08/2006 ......................................................................................................................................... 4-72
TRANSMISSION
SINGLE SPEED
D/B 08/2006⇒ ......................................................................................................................................... 4-86
⇒D/B 08/2006 ......................................................................................................................................... 4-84
WORK, REAR DRIVE, AND BRAKE/TAIL LIGHTS ........................................................................................... 4-28
Listed below are abbreviations used in parts manuals to denote the following expressions:
1. Determine the function and application of the part 9. Quantities shown are for one assembly. The
required. Turn to the Sections Page. Choose the quantities of the subpart BEARING CAP are
general area of reference most likely to include indicated as two and two. This means two per
the part. CASE assembly.
2. Turn to the section you chose. Use the Section 10. Serial number breaks identify the most current
Table of Contents to determine the assembly which parts information and are shown as follows:
would normally contain the part required. Then ⇒ S/N D001H-2628
locate the part on the assembly breakdown page. Indicates last serial number affected.
S/N D001H-2629 ⇒
WHEN THE PART NUMBER IS NOT KNOWN Indicates the first serial number affected.
AND THE NEXT HIGHER ASSEMBLY IS S/N D001H-1553 ⇔ S/N D001H-3291
KNOWN: Indicates a range of serial numbers affected.
3. Determine the assembly the required part is used ECN numbers for pending serial numbers are
on. Turn to the Table of Contents on Page i. shown to allow for the inclusion of the most current
parts information and are identified as follows:
4. Locate the assembly the required part is used on ⇒ S/N Pending Per ECN 63243
and turn to the page indicated for that assembly. Indicates a pending serial number for last unit
Then locate the part on the assembly breakdown affected.
page. S/N Pending Per ECN 63243 ⇒
Indicates a pending serial number for first unit
WHEN THE PART NUMBER IS KNOWN: affected.
5. Use the Numerical Index on Page 14-1 to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
⇒ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00 ⇒
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (. . . . .) within that month for the item affected.
indicate that the part is either Not Serviced D/B 3/00 ⇔ D/B 4/00
Separately or there is a reference to another figure. Indicates a range of production dates of the
A figure reference is denoted by a pointing hand item affected.
followed by a figure number in the DESCRIPTION
column (☞Figure 10) Contact your local dealer for Hyster lift trucks for
serial number information for items with a ECN or
7. Keys are used to show two or more similar a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERING PARTS:
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Hyster lift trucks.
(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957, 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 MANUAL. This manual has information that the operator
must know for inspection and operation of the lift truck.
SERVICE MAINTENANCE MANUALS, which provide service and overhaul procedures, and PARTS MANUALS
with complete replacement part identification, are available at a nominal fee from your Hyster dealer to assist
users in effectively maintaining Hyster lift trucks in a safe, useful condition. See the list below for information on
ordering specific publications for this model lift truck.
1 FRAME
1 FRAME
UNIT CODE F001
03/2007 EUROPE
SECTION 1
FRAME
DESCRIPTION PAGE
CAB
WINDOWS AND WINDOW WIPER SYSTEM ................................................................................................ 1-62
WIRING AND ATTACHING PARTS................................................................................................................. 1-60
CAB AND ATTACHING PARTS
WITH PVC DOORS ........................................................................................................................................ 1-56
WITH STEEL DOORS .................................................................................................................................... 1-48
CAB ASSEMBLY
WITH STEEL DOORS .................................................................................................................................... 1-46
CAB DOORS
PVC................................................................................................................................................................. 1-58
CONTROL LEVER LABELS............................................................................................................................... 1-32
COUNTERWEIGHT
D/B 04/2007⇒ ................................................................................................................................................ 1-12
⇒D/B 04/2007 ................................................................................................................................................ 1-10
COWL MOUNTING .............................................................................................................................................. 1-8
ELECTRONIC LEVER LABELS
AUXILIARY DUAL FUNCTION ....................................................................................................................... 1-36
AUXILIARY SINGLE FUNCTION.................................................................................................................... 1-34
FENDER EXTENSIONS AND MUD GUARDS
WITH WIDE TREAD ......................................................................................................................................... 1-6
FLOORPLATES AND COVERS ........................................................................................................................... 1-4
FORKS ............................................................................................................................................................... 1-42
FULL SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS ....................................................................................... 1-20
WITH LIMITED BACK TILT
D/B 09/2006⇒............................................................................................................................................. 1-24
FULL SUSPENSION SWIVEL SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS ....................................................................................... 1-22
WITH LIMITED BACK TILT
D/B 09/2006⇒............................................................................................................................................. 1-26
HOOD................................................................................................................................................................... 1-2
JOYSTICK LABELS............................................................................................................................................ 1-38
WITH RETURN TO SET TILT......................................................................................................................... 1-40
LABELS
EXTERIOR...................................................................................................................................................... 1-28
INTERIOR....................................................................................................................................................... 1-30
LOAD BACKREST EXTENSION........................................................................................................................ 1-44
NON SUSPENSION SEAT
WITHOUT ELECTRONIC CONTROLS .......................................................................................................... 1-16
OVERHEAD GUARD.......................................................................................................................................... 1-14
SEMI SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS ....................................................................................... 1-18
STEEL DOOR
LEFT HAND .................................................................................................................................................... 1-54
STEEL DOOR AND HEATER ASSEMBLY
RIGHT HAND.................................................................................................................................................. 1-50
WEATHER PROTECTION.................................................................................................................................. 1-64
HOOD
FOOTNOTES:
a Diesel
b LPG
1 1583611 Capscrew..................................................................................................................... 2
2 1566545 Cowl............................................................................................................................. 1
3 1530243 Insert............................................................................................................................ 2
4 1640776 Insert............................................................................................................................ 7
5 1605990 Capscrew..................................................................................................................... 7
1-9
UNIT CODE F001
EUROPE 03/2007
COUNTERWEIGHT
(⇒D/B 04/2007)
COUNTERWEIGHT
(D/B 04/2007⇒)
OVERHEAD GUARD
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
KEY:
A: Without Arm Controls
B: With Arm Controls
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Not Illustrated
KEY:
A: Full Suspension (Vinyl)
B: Full Suspension (Cloth)
C: Full Suspension (Vinyl with Electronic Control Arm)
D: Full Suspension (Cloth with Electronic Control Arm)
QTY
ITEM PART NO. DESCRIPTION A B C D
FOOTNOTES:
a Not Illustrated
FOOTNOTES:
a Not Illustrated
KEY:
A: Full Suspension (Vinyl)
B: Full Suspension (Cloth)
C: Full Suspension (Vinyl with Electronic Control Arm)
D: Full Suspension (Cloth with Electronic Control Arm)
QTY
ITEM PART NO. DESCRIPTION A B C D
LABELS
EXTERIOR
FOOTNOTES:
a Diesel Only
b LPG Only
LABELS
INTERIOR
1 a .. . . . Nameplate ................................................................................................................... 1
2 389688 Cover ........................................................................................................................... 1
3 2038100 Label (Drive Train Protection) ...................................................................................... 1
4 1589377 Label (Basic Powershift Transmission) ........................................................................ 1
5 1589397 Label (DuraMatch Transmission) ................................................................................. 1
6 1534660 Label (Patents and Trademarks).................................................................................. 1
7 170658 Rivet............................................................................................................................. 4
8 1374775 Label (Radial Tire Warning)......................................................................................... 1
9 1365830 Label (Caution Soot Trap)............................................................................................ 1
10 2074210 Label (Park Brake Warning)......................................................................................... 1
11 1324480 Label (Battery Switch) ................................................................................................. 1
12 1365843 Label (Diesel Caution Soot Trap)................................................................................. 1
FOOTNOTES:
a Contact Your Local Hyster Dealer
JOYSTICK LABELS
JOYSTICK LABELS
WITH RETURN TO SET TILT
KEY:
A: 80 mm x 40 mm (4 in. x 1.5 in.) Standard Taper
B: 100 mm x 40 mm (4 in. x 1.5 in.) Full Bottom Taper
QTY
ITEM PART NO. DESCRIPTION A B
1-43
UNIT CODE F001
EUROPE 03/2007
CAB ASSEMBLY
WITH STEEL DOORS
FOOTNOTES:
a ⇒ PENDING PER ECN 10431595
b PENDING PER ECN 10431595 ⇒
FOOTNOTES:
a Seat Restriction
b ⇒ PENDING PER ECN 10431595
c PENDING PER ECN 10431595 ⇒
FOOTNOTES:
a Not Illustrated
b ⇒ PENDING PER ECN 10431595
c PENDING PER ECN 10431595 ⇒
1-53
UNIT CODE F001
EUROPE 03/2007
STEEL DOOR
LEFT HAND
FOOTNOTES:
a Not Illustrated
b ⇒ PENDING PER ECN 10431595
c PENDING PER ECN 10431595 ⇒
FOOTNOTES:
a Seat Restriction
CAB DOORS
PVC
KEY:
A: Right Hand
B: Left Hand
QTY
ITEM PART NO. DESCRIPTION A B
CAB
WIRING AND ATTACHING PARTS
FOOTNOTES:
a ⇒ PENDING PER ECN 10431595
b PENDING PER ECN 10431595 ⇒
CAB
WINDOWS AND WINDOW WIPER SYSTEM
FOOTNOTES:
a ⇒ PENDING PER ECN 10431595
b PENDING PER ECN 10431595 ⇒
WEATHER PROTECTION
1-66
UNIT CODE F001
03/2007 EUROPE
2 ENGINES
2 ENGINES
UNIT CODE F001
03/2007 EUROPE
SECTION 2
ENGINES
DESCRIPTION PAGE
SECTION 2
ENGINES (Continued)
DESCRIPTION PAGE
MAZDA 2.0L
⇒S/N F001B02042D................................................................................................................................... 2-20
S/N F001B02043D⇒................................................................................................................................... 2-22
YANMAR 2.6L DIESEL ................................................................................................................................... 2-56
GEAR HOUSING
YANMAR 2.6L DIESEL ................................................................................................................................... 2-58
INTAKE AND EXHAUST MANIFOLDS
MAZDA 2.0L ................................................................................................................................................... 2-24
YANMAR 2.6L DIESEL ................................................................................................................................... 2-54
LUBRICATION SYSTEM
YANMAR 2.6L DIESEL ................................................................................................................................... 2-72
OIL PAN
YANMAR 2.6L DIESEL ................................................................................................................................... 2-60
OIL PUMP AND FILTER
LPG (MAZDA 2.0L) ......................................................................................................................................... 2-38
OVERHEAD EXHAUST
MAZDA 2.0L
WITH CATALYTIC CONVERTER ................................................................................................................ 2-14
MAZDA 2.0L LPG
WITHOUT CATALYTIC CONVERTER
⇒S/N F001B02723D ............................................................................................................................... 2-16
WITHOUT CATALYTIC CONVERTER
YANMAR 2.6L ............................................................................................................................................. 2-48
TIMING GEAR COVER AND OIL PAN
MAZDA 2.0L
LPG ............................................................................................................................................................. 2-36
WATER PUMP
YANMAR 2.6L DIESEL ................................................................................................................................... 2-70
2-3
UNIT CODE F001
EUROPE 03/2007
ENGINE MOUNTING
KEY:
A: Mazda Engine
B: Yanmar Diesel Engine
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: Mazda Engine
B: Yanmar Diesel Engine
QTY
ITEM PART NO. DESCRIPTION A B
1 1375642 Fan....................................................................................................................... 1 1
2 1528140 Spacer ................................................................................................................. 1 ..
2 1377781 Spacer ................................................................................................................. .. 1
3 293619 Capscrew............................................................................................................. 4 4
4 296418 Washer ................................................................................................................ 4 4
2-7
UNIT CODE F001
EUROPE 03/2007
COOLING SYSTEM
MAZDA 2.0L
LPG
(⇒PENDING PER ECN 10402518)
KEY:
A: Serpentine Radiator
B: Square Wave Radiator
QTY
ITEM PART NO. DESCRIPTION A B
COOLING SYSTEM
MAZDA 2.0L
LPG
(PENDING PER ECN 10402518⇒)
KEY:
A: Serpentine Radiator
B: Square Wave Radiator
QTY
ITEM PART NO. DESCRIPTION A B
COUNTERWEIGHT EXHAUST
MAZDA 2.0L
WITH CATALYTIC CONVERTER
1 1510115 Capscrew..................................................................................................................... 2
2 1528938 Washer ........................................................................................................................ 4
3 1528930 Isolator ......................................................................................................................... 2
4 1649471 Spacer ......................................................................................................................... 2
5 1532585 Washer ........................................................................................................................ 2
6 1582222 Lock Nut....................................................................................................................... 2
7 68968 Clamp .......................................................................................................................... 3
8 1534174 Exhaust Pipe ............................................................................................................... 1
9 1469405 Nut ............................................................................................................................... 2
10 292683 Lockwasher.................................................................................................................. 2
11 1469379 Gasket ......................................................................................................................... 1
12 1560278 Catalytic Converter ...................................................................................................... 1
13 1495501 Bolt .......................................................................................................................... 2
14 1495502 Bolt .......................................................................................................................... 2
15 1547712 Gasket ......................................................................................................................... 1
16 1460477 Nut ............................................................................................................................... 2
17 1532523 Bracket......................................................................................................................... 1
18 1589312 Exhaust Pipe ............................................................................................................... 1
19 2060957 Muffler.......................................................................................................................... 1
20 1585595 Exhaust Shield............................................................................................................. 1
21 1528937 Gasket ......................................................................................................................... 1
22 1585483 Exhaust Pipe ............................................................................................................... 1
23 1582222 Lock Nut....................................................................................................................... 4
24 1396518 Plug Assembly ............................................................................................................. 1
25 1509103 Ring (Copper) .............................................................................................................. 1
26 1533639 Cover ........................................................................................................................... 1
27 1347045 Fastener....................................................................................................................... 3
OVERHEAD EXHAUST
MAZDA 2.0L
WITH CATALYTIC CONVERTER
1 1510115 Capscrew..................................................................................................................... 2
2 1528938 Washer ........................................................................................................................ 4
3 1528930 Isolator ......................................................................................................................... 2
4 1528934 Spacer ......................................................................................................................... 2
5 1532585 Washer ........................................................................................................................ 2
6 1582222 Lock Nut....................................................................................................................... 2
7 68968 Clamp .......................................................................................................................... 3
8 1534174 Exhaust Pipe ............................................................................................................... 1
9 1469405 Nut ............................................................................................................................... 2
10 292683 Lockwasher.................................................................................................................. 2
11 1469379 Gasket ......................................................................................................................... 1
12 1560278 Catalytic Converter ...................................................................................................... 1
13 1495501 Bolt .......................................................................................................................... 2
14 1495502 Bolt .......................................................................................................................... 2
15 1547712 Gasket ......................................................................................................................... 1
16 1460477 Nut ............................................................................................................................... 2
17 1532523 Bracket......................................................................................................................... 1
18 1531829 Exhaust Pipe ............................................................................................................... 1
19 2060957 Muffler.......................................................................................................................... 1
20 1585595 Exhaust Shield............................................................................................................. 1
21 1528937 Gasket ......................................................................................................................... 1
22 1585483 Exhaust Pipe ............................................................................................................... 1
23 1582222 Lock Nut....................................................................................................................... 4
24 1396518 Plug Assembly ............................................................................................................. 1
25 1509103 Ring (Copper) .............................................................................................................. 1
26 1610940 Tail Pipe ....................................................................................................................... 1
27 1510117 Capscrew..................................................................................................................... 3
28 320159 Washer ........................................................................................................................ 3
29 2021394 Cover ........................................................................................................................... 1
OVERHEAD EXHAUST
MAZDA 2.0L LPG
WITHOUT CATALYTIC CONVERTER
(⇒S/N F001B02723D)
FOOTNOTES:
a ⇒ S/N F001B01812D
b S/N F001B01813D ⇒
EXHAUST SYSTEM
MAZDA 2.0L
WITHOUT CATALYTIC CONVERTER
(S/N F001B02723D⇒)
FOOTNOTES:
a ⇒ S/N F001B02898E
b S/N F001B02899E ⇒
1 1534417 Capscrew..................................................................................................................... 3
2 1527884 Capscrew..................................................................................................................... 2
3 1624727 Bracket......................................................................................................................... 1
4 292682 Lockwasher.................................................................................................................. 10
5 292517 Capscrew..................................................................................................................... 10
6 1506572 Adapter ........................................................................................................................ 1
7 296422 Washer ........................................................................................................................ 6
8 1528415 Capscrew..................................................................................................................... 6
9 360387 Sealant ........................................................................................................................ AR
10 1605467 Flywheel (With Ring Gear) .......................................................................................... 1
11 2072918 Capscrew..................................................................................................................... 6
12 303150 Pin ............................................................................................................................... 2
13 296424 Washer ........................................................................................................................ 6
14 1553266 Flywheel Housing ........................................................................................................ 1
15 1565832 Bracket......................................................................................................................... 1
16 1586013 Capscrew..................................................................................................................... 1
17 240072 Static Strap .................................................................................................................. 1
18 1460477 Nut ............................................................................................................................... 1
19 1623093 Bracket......................................................................................................................... 1
FOOTNOTES:
a Cut To Length
FOOTNOTES:
a Black
b Red/Brown
CYLINDER BLOCK
LPG
MAZDA 2.0L
CARBURETOR
LPG
MAZDA 2.0L
KEY:
A: Gasoline
B: LPG
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a 0.25 mm
b 0.50 mm
c 0.75 mm
d Standard
DELAY VALVE
MAZDA 2.0L
LPG
(S/N F001B02574D⇒)
COOLING SYSTEM
YANMAR 2.6L DIESEL
(⇒PENDING PER ECN 10402518)
COOLING SYSTEM
YANMAR 2.6L DIESEL
(PENDING PER ECN 10402518⇒)
OVERHEAD EXHAUST
WITHOUT CATALYTIC CONVERTER
YANMAR 2.6L
FOOTNOTES:
a ⇒ S/N F001B02898E
b S/N F001B02899E ⇒
EXHAUST
WITH PURIFIER
YANMAR 2.6L DIESEL
FOOTNOTES:
a Overhead Exhaust Only
EXHAUST
WITHOUT PURIFIER
YANMAR 2.6L DIESEL
FOOTNOTES:
a Not Illustrated
b Overhead Exhaust Only
FOOTNOTES:
a S/N F001B02057D ⇒
b ⇒ PENDING PER ECN 104584
c PENDING PER ECN 104584 ⇒
GEAR HOUSING
YANMAR 2.6L DIESEL
OIL PAN
YANMAR 2.6L DIESEL
CYLINDER HEAD
YANMAR 2.6L DIESEL
CYLINDER BLOCK
YANMAR 2.6L DIESEL
WATER PUMP
YANMAR 2.6L DIESEL
LUBRICATION SYSTEM
YANMAR 2.6L DIESEL
2-74
UNIT CODE F001
03/2007 EUROPE
3 FUEL SYSTEM
3 FUEL SYSTEM
UNIT CODE F001
03/2007 EUROPE
SECTION 3
FUEL SYSTEM
DESCRIPTION PAGE
1 1652929 Silencer........................................................................................................................ 1
2 1580068 Strap ............................................................................................................................ 1
3 112989 Clamp .......................................................................................................................... 1
4 1502032 Hose ............................................................................................................................ 1
5 119236 Clamp .......................................................................................................................... 4
6 2055193 Air Filter Assembly (☞ Figure 3-6) ............................................................................. 1
7 2095807 Hose ............................................................................................................................ 1
8 2095413 Hose (Dirty Air) ............................................................................................................ 1
9 1394008 Clamp .......................................................................................................................... 1
10 1581438 Elbow ........................................................................................................................... 1
11 1581439 Retainer ....................................................................................................................... 1
12 1502079 Grommet...................................................................................................................... 1
13 1501848 Bracket......................................................................................................................... 1
14 1527879 Capscrew..................................................................................................................... 2
15 1530243 Insert............................................................................................................................ 3
16 1583611 Capscrew..................................................................................................................... 3
FOOTNOTES:
a ⇒ S/N F001B02111D
b S/N F001B02112D ⇒
3-11
UNIT CODE F001
EUROPE 03/2007
KEY:
A: LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
FUEL SYSTEM
MAZDA 2.0L
FUEL SYSTEM
MAZDA 2.0L
FOOTNOTES:
a German Market
3-17
UNIT CODE F001
EUROPE 03/2007
FOOTNOTES:
a ⇒ PENDING PER ECN 10419402
b PENDING PER ECN 10419402 ⇒
3-27
UNIT CODE F001
EUROPE 03/2007
FOOTNOTES:
a For Germany Market, Not illustrated.
3-31
UNIT CODE F001
EUROPE 03/2007
FUEL SYSTEM
DIESEL
FOOTNOTES:
a DS Models Only
b Standard Models Only
FUEL FILTER
YANMAR 2.6L DIESEL
FUEL INJECTION
YANMAR 2.6L DIESEL
THROTTLE LINKAGE
MAZDA 2.0L
1 1564752 Screw........................................................................................................................... 2
2 296378 Washer ........................................................................................................................ 2
3 2063842 Throttle Position Sensor .............................................................................................. 1
4 1527879 Capscrew..................................................................................................................... 7
5 251099 Adhesive ...................................................................................................................... AR
6 d 1556962 Shaft ............................................................................................................................ 1
6 b 1521005 Shaft ............................................................................................................................ 1
6 c 1654754 Shaft ............................................................................................................................ 1
7 1530971 Retaining Ring ............................................................................................................. 1
8 a 1538488 Throttle Base ............................................................................................................... 1
8 c 1654411 Throttle Base ............................................................................................................... 1
8 1524267 Bushing ................................................................................................................... 1
9 1582303 Spring (Inner)............................................................................................................... 1
10 1582302 Spring (Outer).............................................................................................................. 1
11 1514429 Nut (Flange)................................................................................................................. 2
12 2071181 Pedal (Standard).......................................................................................................... 1
13 329069 Nut ............................................................................................................................... 1
14 1530311 Screw (Stop) ................................................................................................................ 1
15 320156 Washer ........................................................................................................................ 2
16 302443 Pin ............................................................................................................................... 1
17 1538782 Push Rod Assembly .................................................................................................... 1
17 1538490 Pushrod ................................................................................................................... 1
17 2308541 Jam Nut ................................................................................................................... 2
17 2027949 Joint Ball.................................................................................................................. 2
18 1399802 Bolt .............................................................................................................................. 1
19 1538162 Bellcrank ...................................................................................................................... 1
20 302437 Roll Pin (Monotrol Pedal) ............................................................................................. 1
21 1480237 Clip Nut ........................................................................................................................ 2
22 302400 Locknut ........................................................................................................................ 1
23 1609374 Bracket (Throttle Cable)............................................................................................... 1
24 1517361 Lock Ring..................................................................................................................... 1
25 126 Rod End Pin ................................................................................................................ 1
26 1562088 Clip .............................................................................................................................. 4
27 1542082 Bracket (RH Frame) ..................................................................................................... 1
28 1530243 Insert............................................................................................................................ 2
29 1543691 Clamp (Swivel)............................................................................................................. 1
30 1542440 Clamp (Swivel)............................................................................................................. 1
31 1569544 Bracket (Engine) .......................................................................................................... 1
32 2067391 Throttle Cable .............................................................................................................. 1
33 1608412 Monotrol Pedal Assembly (☞ Figure 3-20) ................................................................ 1
33 1340470 Pad .......................................................................................................................... 1
FOOTNOTES:
a ⇒ S/N F001B02997E
b D/B 09/2005 ⇒ S/N F001B02997E
c S/N F001B02998E ⇒
d ⇒ D/B 09/2005
4 ELECTRICAL SYSTEM
4 ELECTRICAL SYSTEM
UNIT CODE F001
03/2007 EUROPE
SECTION 4
ELECTRICAL SYSTEM
DESCRIPTION PAGE
SECTION 4
ELECTRICAL SYSTEM (Continued)
DESCRIPTION PAGE
4-3
UNIT CODE F001
EUROPE 03/2007
ELECTRICAL SYSTEM
CHASSIS
1 1582464 Fastener....................................................................................................................... 6
2 1582442 Clip .............................................................................................................................. 1
3 e 1585436 Bracket......................................................................................................................... 1
3 f 1617080 Bracket (Hood Switch) ................................................................................................. 1
4 1529366 Capscrew..................................................................................................................... 1
5 a 1616981 Battery Tray.................................................................................................................. 1
5 b 2090661 Battery Tray.................................................................................................................. 1
6 1402883 Fuse Puller .................................................................................................................. 1
7 1534417 Capscrew..................................................................................................................... 4
8 1502543 Nut (Flange)................................................................................................................. 1
9 c 2063093 Power Distribution Module (☞ Figure 4-7) ................................................................. 1
9 d 2090613 Power Distribution Module (☞ Figure 4-8) ................................................................. 1
9 1559928 Seal ......................................................................................................................... 1
10 1500912 Clip .............................................................................................................................. 6
11 1593331 Connector (Mazda Only) ............................................................................................. 1
12 g 1527264 Horn............................................................................................................................. 1
12 h 1618978 Horn............................................................................................................................. 1
13 1527880 Capscrew..................................................................................................................... 4
14 1480237 Clip Nut ........................................................................................................................ 4
15 e 2075026 Wire Harness (Chassis) (Mazda 2.0L) (☞ Figure 4-18) ............................................ 1
15 f 2085948 Wire Harness (Chassis) (Mazda 2.0L) (☞ Figure 4-19) ............................................ 1
15 e 2074736 Wire Harness (Chassis) (Yanmar 2.6L Diesel) (☞ Figure 4-20) ................................ 1
15 f 2085950 Wire Harness (Chassis) (Yanmar 2.6L Diesel) (☞ Figure 4-21) ................................ 1
16 1383331 Battery (Wet) ............................................................................................................... 1
17 2065745 Link (Battery Hold Down)............................................................................................. 1
18 1502543 Nut (Flange)................................................................................................................. 1
19 1540805 Cap .............................................................................................................................. 1
20 a 1638706 Link (Battery Hold Down)............................................................................................. 1
20 b 1641368 Link (Battery Hold Down)............................................................................................. 1
FOOTNOTES:
a ⇒ S/N F001B03123E
b S/N F001B03124E ⇒
c ⇒ D/B 07/2006
d D/B 07/2006 ⇒
e ⇒ D/B 08/2006
f D/B 08/2006 ⇒
g ⇒ D/B 09/2006
h D/B 09/2006 ⇒
IMPACT SENSOR
1 1535166 Bracket......................................................................................................................... 1
2 1500912 Clip .............................................................................................................................. 2
3 1582464 Fastener....................................................................................................................... 2
4 2079281 Wire Harness (Impact Sensor) .................................................................................... 1
5 1489655 Connector (4 Way) .................................................................................................. 1
6 1330416 Secondary Lock....................................................................................................... 1
7 1330437 Terminal (Pin) .......................................................................................................... 4
8 1489656 Connector (4-Way) .................................................................................................. 2
9 1489657 Secondary Lock....................................................................................................... 2
10 1330438 Terminal (Socket) .................................................................................................... 8
11 1561759 Clamp (Swivel)............................................................................................................. 2
12 1542439 Clamp .......................................................................................................................... 2
13 1502055 Clamp .......................................................................................................................... 1
14 1527879 Capscrew..................................................................................................................... 2
15 2079843 Impact Sensor ............................................................................................................. 1
16 1489655 Connector (4 Way) .................................................................................................. 1
17 1330416 Secondary Lock....................................................................................................... 1
18 1330433 Pin ........................................................................................................................... 4
19 1502053 Clamp .......................................................................................................................... 1
FOOTNOTES:
a ⇒ D/B 08/2006
b D/B 08/2006 ⇒
4-13
UNIT CODE F001
EUROPE 03/2007
31 296380 Lockwasher.................................................................................................................. 1
32 1529366 Capscrew..................................................................................................................... 2
33 1502061 Clamp .......................................................................................................................... 1
34 1599845 Starter.......................................................................................................................... 1
34 1599847 Ball Bearing ............................................................................................................. 1
34 1599848 Ball Bearing ............................................................................................................. 1
34 1599850 Screw ...................................................................................................................... 4
34 1599851 Brush ....................................................................................................................... 2
34 1599853 Spring ...................................................................................................................... 4
34 1599860 Pinion ...................................................................................................................... 1
34 1599867 Housing ................................................................................................................... 1
35 1528889 Capscrew..................................................................................................................... 1
36 1599843 Clamp .......................................................................................................................... 2
FOOTNOTES:
a ⇒ D/B 08/2006
b D/B 08/2006 ⇒
4-17
UNIT CODE F001
EUROPE 03/2007
COWL ELECTRICAL
FOOTNOTES:
a Four Function
b Not Illustrated
c Three Function
d With Electronic Hydraulics
e Without Electronic Hydraulics
INSTRUMENT CLUSTER
FOOTNOTES:
a Remove Panels From Overlay as Required For Truck Configuration.
b ⇒ S/N F001B02588D
c S/N F001B02589D ⇒
d ⇒ S/N F001B02615D
e S/N F001B02616D ⇒
JOYSTICK
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a ⇒ PENDING PER ECN 10431564
b PENDING PER ECN 10431564 ⇒
c D/B 11/2006 ⇒ PENDING PER ECN 10431564
d D/B 11/2006 ⇒ PENDING PER ECN 10431564
e ⇒ D/B 11/2006
f D/B 11/2006 ⇒
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1527880 Capscrew..................................................................................................................... 4
2 2070561 Turn Signal (RH Front)................................................................................................. 1
2 2070563 Cap (Black Plastic) .................................................................................................. 2
2 1493466 Connector................................................................................................................ 1
2 1330415 Secondary Lock....................................................................................................... 1
2 1330437 Terminal (Pin) .......................................................................................................... 3
2 2070562 Turn Signal (LH Front) ................................................................................................. 1
2 2070563 Cap (Black Plastic) .................................................................................................. 2
2 1493466 Connector................................................................................................................ 1
2 1330415 Secondary Lock....................................................................................................... 1
2 1330437 Terminal (Pin) .......................................................................................................... 3
3 e 2070553 Work Light (RH Front).................................................................................................. 1
3 f 2098086 Work Light (RH Front).................................................................................................. 1
3 2098082 Bulb (Halogen) ........................................................................................................ 1
3 e 2070554 Work Light (LH Front) .................................................................................................. 1
3 f 2098087 Work Light (LH Front) .................................................................................................. 1
3 2098082 Bulb (Halogen) ........................................................................................................ 1
4 c 2074737 Wire Harness (Lights) (☞ Figure 4-32) ...................................................................... 1
4 d 2090087 Wire Harness (Lights) (☞ Figure 4-33) ...................................................................... 1
5 1537551 Clip Nut ........................................................................................................................ 2
6 1560447 Grommet (RH) ............................................................................................................. 1
7 2056824 Light (Stop,Turn,Tail, And Back-Up)............................................................................. 2
7 2056826 Reflector (Tail) ............................................................................................................. 2
7 .. . . . Bracket (☞ Figure 1-2) ............................................................................................... 2
8 1565125 Screw........................................................................................................................... 4
9 1302024 Guard........................................................................................................................... 1
10 a 1581670 Strobe Light Assembly (☞ Figure 13-1) ..................................................................... 1
10 b 1654013 Strobe Light Assembly (☞ Figure 13-2) ..................................................................... 1
11 1565076 Bracket......................................................................................................................... 1
12 1586759 Capscrew..................................................................................................................... 2
13 1586495 Capscrew..................................................................................................................... 2
14 1531001 Insert............................................................................................................................ 2
15 1586428 Nut ............................................................................................................................... 2
16 e 2064836 Work Light (Rear) ........................................................................................................ 1
16 f 2098083 Work Light (Rear) ........................................................................................................ 1
17 1539584 Grommet (Oval) ........................................................................................................... 1
18 1563841 Connector .................................................................................................................... 1
19 d 2095895 Jumper Harness .......................................................................................................... 1
19 1514597 Connector................................................................................................................ 1
19 1514598 Secondary Lock....................................................................................................... 1
19 1484709 Terminal (Pin) .......................................................................................................... 4
19 1634047 Resistor ................................................................................................................... 3
20 d 1644398 Swivel Tie .................................................................................................................... 1
21 d 1606544 Clamp .......................................................................................................................... 1
FOOTNOTES:
a ⇒ PENDING PER ECN 10298201
b PENDING PER ECN 10298201 ⇒
c ⇒ PENDING PER ECN 10419449
d PENDING PER ECN 10419449 ⇒
4-31
UNIT CODE F001
EUROPE 03/2007
FOOTNOTES:
a ⇒ D/B 08/2006
b D/B 08/2006 ⇒
c ⇒ D/B 09/2005
d D/B 09/2005⇔D/B 08/2006
1 1553897 Capscrew..................................................................................................................... 2
2 1589621 Sensor (Mast) .............................................................................................................. 1
2 1493466 Connector................................................................................................................ 1
2 1330415 Secondary Lock....................................................................................................... 1
2 1330437 Terminal (Pin) .......................................................................................................... 3
2 98644 Grommet ................................................................................................................. 2
2 175944 Heat Shrink Tube..................................................................................................... AR
3 1587839 Bracket (Sensor) .......................................................................................................... 1
4 302398 Nut ............................................................................................................................... 2
5 1595731 Bracket (Harness)........................................................................................................ 1
4-35
UNIT CODE F001
EUROPE 03/2007
WIRE HARNESS
CHASSIS
MAZDA 2.0L
(⇒D/B 08/2006)
WIRE HARNESS
CHASSIS
MAZDA 2.0L
(⇒D/B 08/2006)
10 1323579 Seal..................................................................................................................... 5
10 1327164 Plug..................................................................................................................... 2
10 1330281 Terminal .............................................................................................................. 5
10 1521989 Terminal .............................................................................................................. 1
10 1402888 Seal..................................................................................................................... 1
11 .. . . . Connector Assembly (Power Distribution Module) .................................................. 1
11 1521183 Connector ........................................................................................................... 1
11 1521188 Secondary Lock .................................................................................................. 1
11 1323579 Seal..................................................................................................................... 7
11 1327164 Plug..................................................................................................................... 1
11 1330281 Terminal .............................................................................................................. 4
11 1521989 Terminal .............................................................................................................. 3
12 1534828 Clip .......................................................................................................................... 1
13 .. . . . Connector Assembly (Hydraulic Filter) .................................................................... 1
13 1329152 Connector ........................................................................................................... 1
13 1329151 Secondary Lock .................................................................................................. 1
13 1330281 Terminal .............................................................................................................. 2
13 1402888 Seal..................................................................................................................... 2
14 .. . . . Connector Assembly (End Cap).............................................................................. 1
14 1329150 Connector ........................................................................................................... 1
14 1327164 Plug..................................................................................................................... 2
14 1329151 Secondary Lock .................................................................................................. 1
15 .. . . . Connector Assembly (Power Distribution Module) .................................................. 1
15 1521185 Connector ........................................................................................................... 1
15 1521188 Secondary Lock .................................................................................................. 1
15 1323579 Seal..................................................................................................................... 7
15 1327164 Plug..................................................................................................................... 1
15 1330281 Terminal .............................................................................................................. 5
15 1521989 Terminal .............................................................................................................. 2
16 .. . . . Connector Assembly (Power Distribution Module) .................................................. 1
16 1521186 Connector ........................................................................................................... 1
16 1521188 Secondary Lock .................................................................................................. 1
16 1323579 Seal..................................................................................................................... 7
16 1327164 Plug..................................................................................................................... 1
16 1521989 Terminal .............................................................................................................. 7
17 .. . . . Connector Assembly (Accessory 2) ........................................................................ 1
17 1514602 Connector ........................................................................................................... 1
17 1514603 Secondary Lock .................................................................................................. 1
17 1554359 Terminal .............................................................................................................. 4
18 .. . . . Connector Assembly (End Cap).............................................................................. 1
18 1514597 Connector ........................................................................................................... 1
18 1330439 Insulator .............................................................................................................. 4
19 1572588 Hood Switch ............................................................................................................ 1
20 .. . . . Connector Assembly (Seat Harness) ...................................................................... 1
20 1541991 Connector ........................................................................................................... 1
20 1541992 Secondary Lock .................................................................................................. 1
20 1463139 Terminal .............................................................................................................. 8
21 .. . . . Connector Assembly (Alternate Horn Button) ......................................................... 1
21 1490242 Connector ........................................................................................................... 1
WIRE HARNESS
CHASSIS
MAZDA 2.0L
(⇒D/B 08/2006)
21 1402813 Clip...................................................................................................................... 1
21 1330438 Terminal (Socket) ................................................................................................ 2
22 1351681 Connector................................................................................................................ 1
23 1509888 Clip .......................................................................................................................... 2
24 1351681 Connector................................................................................................................ 1
25 .. . . . Connector Assembly (Back-Up Alarm).................................................................... 1
25 1490242 Connector ........................................................................................................... 1
25 1402813 Clip...................................................................................................................... 1
25 1330438 Terminal (Socket) ................................................................................................ 2
26 .. . . . Connector (End Cap) .............................................................................................. 1
26 1329150 Connector ........................................................................................................... 1
26 1329151 Secondary Lock .................................................................................................. 1
26 1327164 Plug..................................................................................................................... 2
27 .. . . . Connector (Coolant Level)....................................................................................... 1
27 1329152 Connector ........................................................................................................... 1
27 1329151 Secondary Lock .................................................................................................. 1
27 1330281 Terminal .............................................................................................................. 2
27 1402888 Seal..................................................................................................................... 2
28 1525577 Connector (With Resistor) (End Cap)...................................................................... 1
29 .. . . . Connector Assembly (Bus Terminal) ....................................................................... 1
29 1489656 Connector (4-Way) .............................................................................................. 1
29 1489657 Secondary Lock .................................................................................................. 1
29 1330438 Terminal (Socket) ................................................................................................ 4
30 .. . . . Connector Assembly (Keyswitch) ............................................................................ 1
30 1493465 Connector ........................................................................................................... 1
30 1330414 Secondary Lock .................................................................................................. 1
30 1330437 Terminal (Pin)...................................................................................................... 2
31 .. . . . Connector Assembly (Keyswitch) ............................................................................ 1
31 1490242 Connector ........................................................................................................... 1
31 1402813 Clip...................................................................................................................... 1
31 1330438 Terminal (Socket) ................................................................................................ 2
32 1534282 Clip .......................................................................................................................... 2
33 1500899 Clip .......................................................................................................................... 1
34 .. . . . Connector Assembly (Transmission Harness) ........................................................ 1
34 1502627 Connector (Socket) ............................................................................................. 1
34 1330438 Terminal (Socket) ................................................................................................ 17
34 1484377 Terminal (Plug).................................................................................................... 6
35 .. . . . Connector Assembly (Engine Harness) .................................................................. 1
35 1531501 Connector ........................................................................................................... 1
35 1330438 Terminal (Socket) ................................................................................................ 8
35 1330439 Insulator .............................................................................................................. 1
35 1484377 Terminal (Plug).................................................................................................... 17
35 1554359 Terminal .............................................................................................................. 3
36 .. . . . Connector Assembly (Lights/Cab Harness) ............................................................ 1
36 1514602 Connector ........................................................................................................... 1
36 1514603 Secondary Lock .................................................................................................. 1
36 1554359 Terminal .............................................................................................................. 4
37 .. . . . Connector Assembly (End Cap) .............................................................................. 1
37 1514597 Connector ........................................................................................................... 1
WIRE HARNESS
CHASSIS
MAZDA 2.0L
(⇒D/B 08/2006)
4-45
UNIT CODE F001
EUROPE 03/2007
WIRE HARNESS
CHASSIS
MAZDA 2.0L
(D/B 08/2006⇒)
WIRE HARNESS
CHASSIS
MAZDA 2.0L
(D/B 08/2006⇒)
10 1323579 Seal..................................................................................................................... 5
10 1327164 Plug..................................................................................................................... 2
10 1330281 Terminal .............................................................................................................. 5
10 1521989 Terminal .............................................................................................................. 1
10 1402888 Seal..................................................................................................................... 1
11 .. . . . Connector Assembly (Power Distribution Module) .................................................. 1
11 1521183 Connector ........................................................................................................... 1
11 1521188 Secondary Lock .................................................................................................. 1
11 1323579 Seal..................................................................................................................... 7
11 1327164 Plug..................................................................................................................... 1
11 1330281 Terminal .............................................................................................................. 4
11 1521989 Terminal .............................................................................................................. 3
12 1534828 Clip .......................................................................................................................... 1
13 .. . . . Connector Assembly (Hydraulic Filter) .................................................................... 1
13 1329152 Connector ........................................................................................................... 1
13 1329151 Secondary Lock .................................................................................................. 1
13 1330281 Terminal .............................................................................................................. 2
13 1402888 Seal..................................................................................................................... 2
14 .. . . . Connector Assembly (End Cap).............................................................................. 1
14 1329150 Connector ........................................................................................................... 1
14 1327164 Plug..................................................................................................................... 2
14 1329151 Secondary Lock .................................................................................................. 1
15 .. . . . Connector Assembly (Power Distribution Module) .................................................. 1
15 1521185 Connector ........................................................................................................... 1
15 1521188 Secondary Lock .................................................................................................. 1
15 1323579 Seal..................................................................................................................... 7
15 1327164 Plug..................................................................................................................... 1
15 1330281 Terminal .............................................................................................................. 5
15 1521989 Terminal .............................................................................................................. 2
16 .. . . . Connector Assembly (Power Distribution Module) .................................................. 1
16 1521186 Connector ........................................................................................................... 1
16 1521188 Secondary Lock .................................................................................................. 1
16 1323579 Seal..................................................................................................................... 7
16 1327164 Plug..................................................................................................................... 1
16 1521989 Terminal .............................................................................................................. 7
17 .. . . . Connector Assembly (Accessory 2) ........................................................................ 1
17 1514602 Connector ........................................................................................................... 1
17 1514603 Secondary Lock .................................................................................................. 1
17 1554359 Terminal .............................................................................................................. 4
18 .. . . . Connector Assembly (End Cap).............................................................................. 1
18 1514597 Connector ........................................................................................................... 1
18 1330439 Insulator .............................................................................................................. 4
19 1402815 Clip .......................................................................................................................... 2
20 .. . . . Connector Assembly (Seat Harness) ...................................................................... 1
20 1541991 Connector ........................................................................................................... 1
20 1541992 Secondary Lock .................................................................................................. 1
20 1463139 Terminal .............................................................................................................. 8
21 .. . . . Connector Assembly (Alternate Horn Button) ......................................................... 1
21 1490242 Connector ........................................................................................................... 1
WIRE HARNESS
CHASSIS
MAZDA 2.0L
(D/B 08/2006⇒)
21 1402813 Clip...................................................................................................................... 1
21 1330438 Terminal (Socket) ................................................................................................ 2
22 1351681 Connector................................................................................................................ 1
23 1509888 Clip .......................................................................................................................... 2
24 1351681 Connector................................................................................................................ 1
25 .. . . . Connector Assembly (Back-Up Alarm).................................................................... 1
25 1490242 Connector ........................................................................................................... 1
25 1402813 Clip...................................................................................................................... 1
25 1330438 Terminal (Socket) ................................................................................................ 2
26 .. . . . Connector (End Cap) .............................................................................................. 1
26 1329150 Connector ........................................................................................................... 1
26 1329151 Secondary Lock .................................................................................................. 1
26 1327164 Plug..................................................................................................................... 2
27 .. . . . Connector (Coolant Level)....................................................................................... 1
27 1329152 Connector ........................................................................................................... 1
27 1329151 Secondary Lock .................................................................................................. 1
27 1330281 Terminal .............................................................................................................. 2
27 1402888 Seal..................................................................................................................... 2
28 1525577 Connector (With Resistor) (End Cap)...................................................................... 1
29 .. . . . Connector Assembly (Bus Terminal) ....................................................................... 1
29 1489656 Connector (4-Way) .............................................................................................. 1
29 1489657 Secondary Lock .................................................................................................. 1
29 1330438 Terminal (Socket) ................................................................................................ 4
30 .. . . . Connector Assembly (Keyswitch) ............................................................................ 1
30 1493465 Connector ........................................................................................................... 1
30 1330414 Secondary Lock .................................................................................................. 1
30 1330437 Terminal (Pin)...................................................................................................... 2
31 .. . . . Connector Assembly (Keyswitch) ............................................................................ 1
31 1490242 Connector ........................................................................................................... 1
31 1402813 Clip...................................................................................................................... 1
31 1330438 Terminal (Socket) ................................................................................................ 2
32 1534282 Clip .......................................................................................................................... 2
33 1500899 Clip .......................................................................................................................... 1
34 .. . . . Connector Assembly (Transmission Harness) ........................................................ 1
34 1525567 Connector ........................................................................................................... 1
34 1529046 Secondary Lock .................................................................................................. 1
34 1484377 Terminal (Plug).................................................................................................... 1
34 1463139 Terminal .............................................................................................................. 11
35 .. . . . Connector Assembly (Transmission Harness) ........................................................ 1
35 1531973 Connector ........................................................................................................... 1
35 1531974 Secondary Lock .................................................................................................. 1
35 1463139 Terminal .............................................................................................................. 6
36 .. . . . Connector Assembly (Lights/Cab Harness) ............................................................ 1
36 1514602 Connector ........................................................................................................... 1
36 1514603 Secondary Lock .................................................................................................. 1
36 1554359 Terminal .............................................................................................................. 4
37 .. . . . Connector Assembly (End Cap) .............................................................................. 1
37 1514597 Connector ........................................................................................................... 1
37 1330439 Insulator .............................................................................................................. 4
WIRE HARNESS
CHASSIS
MAZDA 2.0L
(D/B 08/2006⇒)
4-51
UNIT CODE F001
EUROPE 03/2007
WIRE HARNESS
CHASSIS
YANMAR DIESEL 2.6L
(⇒D/B 08/2006)
WIRE HARNESS
CHASSIS
YANMAR DIESEL 2.6L
(⇒D/B 08/2006)
WIRE HARNESS
CHASSIS
YANMAR DIESEL 2.6L
(⇒D/B 08/2006)
WIRE HARNESS
CHASSIS
YANMAR DIESEL 2.6L
(⇒D/B 08/2006)
4-57
UNIT CODE F001
EUROPE 03/2007
WIRE HARNESS
CHASSIS
YANMAR 2.6L DIESEL
(D/B 08/2006⇒)
WIRE HARNESS
CHASSIS
YANMAR 2.6L DIESEL
(D/B 08/2006⇒)
WIRE HARNESS
CHASSIS
YANMAR 2.6L DIESEL
(D/B 08/2006⇒)
WIRE HARNESS
CHASSIS
YANMAR 2.6L DIESEL
(D/B 08/2006⇒)
4-63
UNIT CODE F001
EUROPE 03/2007
WIRE HARNESS
COWL WITH MONOTROL PEDAL
WITH RETURN TO SET TILT
WIRE HARNESS
COWL WITH MONOTROL PEDAL
WITH RETURN TO SET TILT
4-67
UNIT CODE F001
EUROPE 03/2007
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER
WITHOUT RETURN TO SET TILT
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER
WITHOUT RETURN TO SET TILT
4-71
UNIT CODE F001
EUROPE 03/2007
WIRE HARNESS
LPG ENGINE
MAZDA 2.0L
(⇒D/B 08/2006)
WIRE HARNESS
LPG ENGINE
MAZDA 2.0L
(D/B 08/2006⇒)
WIRE HARNESS
DIESEL ENGINE
YANMAR 2.6L
(⇒D/B 08/2006)
WIRE HARNESS
DIESEL ENGINE
YANMAR 2.6L
(D/B 08/2006⇒)
WIRE HARNESS
ELECTRONIC CONTROL VALVE
3 FUNCTION
WIRE HARNESS
ELECTRONIC CONTROL VALVE
4 FUNCTION
WIRE HARNESS
TRANSMISSION
SINGLE SPEED
(⇒D/B 08/2006)
FOOTNOTES:
a ⇒ D/B 09/2005
b D/B 09/2005 ⇒
WIRE HARNESS
TRANSMISSION
SINGLE SPEED
(D/B 08/2006⇒)
WIRE HARNESS
LIGHTS
(⇒PENDING PER ECN 10419449)
WIRE HARNESS
LIGHTS
(PENDING PER ECN 10419449⇒)
WIRE HARNESS
LIGHTS
(PENDING PER ECN 10419449⇒)
5 TR ANSMISSION
5 TRANSMISSION
UNIT CODE F001
03/2007 EUROPE
SECTION 5
TRANSMISSION
DESCRIPTION PAGE
CONTROL VALVE
TRANSMISSION............................................................................................................................................. 5-34
FORWARD CLUTCH
INPUT
⇒PENDING PER ECN 10402574 .............................................................................................................. 5-20
FORWARD CLUTCH (INPUT)
PENDING PER ECN 10402574⇒ .................................................................................................................. 5-30
REVERSE CLUTCH
COUNTER
⇒PENDING PER ECN 10402574 .............................................................................................................. 5-22
REVERSE CLUTCH (COUNTER)
PENDING PER ECN 10402574⇒ .................................................................................................................. 5-32
TORQUE CONVERTER....................................................................................................................................... 5-3
TRANSMISSION
SINGLE SPEED
SHEET 1 OF 2
PENDING PER ECN 10402574⇒........................................................................................................... 5-24
⇒S/N T117M016844 ⇒D/B 09/2006 ........................................................................................................ 5-8
S/N T117M016845⇒ S/N PENDING PER ECN 10402574 D/B 09/2006⇒ ............................................ 5-14
SHEET 2 OF 2
PENDING PER ECN 10402574⇒........................................................................................................... 5-26
⇒S/N T117M016844 ⇒D/B 09/2006 ...................................................................................................... 5-12
S/N T117M016845⇒ S/N PENDING PER ECN 10402574 D/B 09/2006⇒ ............................................ 5-17
TRANSMISSION COOLING
MAZDA 2.0L ..................................................................................................................................................... 5-4
YANMAR 2.6L DIESEL ..................................................................................................................................... 5-6
TRANSMISSION MOUNT .................................................................................................................................... 5-2
1 1501275 Bracket......................................................................................................................... 1
2 2070147 Isolator ......................................................................................................................... 2
3 1566329 Washer ........................................................................................................................ 2
4 292685 Lockwasher.................................................................................................................. 1
5 293697 Capscrew..................................................................................................................... 1
6 292683 Lockwasher.................................................................................................................. 4
7 292531 Capscrew..................................................................................................................... 4
8 a 1550565 Transmission Assembly (Single Speed) ...................................................................... 1
8 b 1632260 Transmission Assembly (Single Speed) ...................................................................... 1
8 c 1646871 Transmission Assembly (Single Speed) ...................................................................... 1
FOOTNOTES:
a ⇒ S/N T117M016844
b S/N T117M016845 ⇒ S/N PENDING PER ECN 10402574
c PENDING PER ECN 10402574 ⇒
KEY:
A: For Use With Mazda Engine
B: For Use With Yanmar Diesel Engine
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Supplied with Serpentine Radiator Only
b ⇒ PENDING PER ECN 10402574
c PENDING PER ECN 10402574 ⇒
5-5
UNIT CODE F001
EUROPE 03/2007
TRANSMISSION COOLING
YANMAR 2.6L DIESEL
FOOTNOTES:
a ⇒ PENDING PER ECN 10402574
b PENDING PER ECN 10402574 ⇒
TRANSMISSION
SINGLE SPEED
SHEET 1 OF 2
(⇒S/N T117M016844 ⇒D/B 09/2006)
TRANSMISSION
SINGLE SPEED
SHEET 1 OF 2
(⇒S/N T117M016844 ⇒D/B 09/2006)
46 1527879 Capscrew..................................................................................................................... 1
1566457 Baffle (Not Illustrated).............................................................................................. 1
5-11
UNIT CODE F001
EUROPE 03/2007
TRANSMISSION
SINGLE SPEED
SHEET 2 OF 2
(⇒S/N T117M016844 ⇒D/B 09/2006)
TRANSMISSION
SINGLE SPEED
SHEET 1 OF 2
(S/N T117M016845⇒ S/N PENDING PER ECN 10402574 D/B 09/2006⇒)
TRANSMISSION
SINGLE SPEED
SHEET 1 OF 2
(S/N T117M016845⇒ S/N PENDING PER ECN 10402574 D/B 09/2006⇒)
46 16484 O-Ring................................................................................................................. 1
47 1612918 Compression Spring (Regulator)............................................................................. 1
48 1612916 Spool (Regulator) .................................................................................................... 1
49 1359458 Capscrew ................................................................................................................ 16
50 2070263 Transducer............................................................................................................... 1
51 1553475 O-Ring ..................................................................................................................... 1
52 1553403 O-Ring ..................................................................................................................... 4
53 1527879 Capscrew..................................................................................................................... 1
54 1569768 Shield........................................................................................................................... 1
55 1380849 Trim.............................................................................................................................. 2
TRANSMISSION
SINGLE SPEED
SHEET 2 OF 2
(S/N T117M016845⇒ S/N PENDING PER ECN 10402574 D/B 09/2006⇒)
5-19
UNIT CODE F001
EUROPE 03/2007
FORWARD CLUTCH
INPUT
(⇒PENDING PER ECN 10402574)
1543105 Clutch Plates and Seals Kit (Includes Items 1, 4-5, 11-13, 15) ................................... 1
1543102 Clutch Pack Plates Kit (Includes Items 11-13)............................................................. 1
1595425 Clutch Pack Seals Kit (Includes Items 1, 4-5, 15)........................................................ 1
REVERSE CLUTCH
COUNTER
(⇒PENDING PER ECN 10402574)
1543105 Clutch Plates and Seals Kit (Includes Items 1, 4-5, 11-13, 15) ................................... 1
1543102 Clutch Pack Plates Kit (Includes Items 11-13)............................................................. 1
1595425 Clutch Pack Seals Kit (Includes Items 1, 4-5, 15)........................................................ 1
TRANSMISSION
SINGLE SPEED
SHEET 1 OF 2
(PENDING PER ECN 10402574⇒)
TRANSMISSION
SINGLE SPEED
SHEET 2 OF 2
(PENDING PER ECN 10402574⇒)
TRANSMISSION
SINGLE SPEED
SHEET 2 OF 2
(PENDING PER ECN 10402574⇒)
5-29
UNIT CODE F001
EUROPE 03/2007
CONTROL VALVE
TRANSMISSION
FOOTNOTES:
a ⇒ S/N T117M0014014
b S/N T117M0014015 ⇒
5-36
UNIT CODE F001
03/2007 EUROPE
6 DRIVE AXLE
6 DRIVE AXLE
UNIT CODE F001
03/2007 EUROPE
SECTION 6
DRIVE AXLE
DESCRIPTION PAGE
DRIVE AXLE
DRIVE AXLE
FOOTNOTES:
a Included With Center Housing
KEY:
A: Narrow Tread
B: Intermediate Tread
C: Wide Tread
QTY
ITEM PART NO. DESCRIPTION A B C
FOOTNOTES:
a Pneumatic
b Snap On Tire
KEY:
A: Narrow Tread
B: Intermediate Tread
QTY
ITEM PART NO. DESCRIPTION A B
1 1471832 Tire Assembly ...................................................................................................... 2 2
1 1462616 Tubeless Bead Seal......................................................................................... 1 1
1 1358178 Tire (Michelin XZM) ......................................................................................... 1 1
1 1471922 Bead Seal Valve .............................................................................................. 1 1
2 2067044 Wheel .................................................................................................................. 2 ..
2 2067046 Wheel .................................................................................................................. .. 2
3 1580426 Side Ring......................................................................................................... 1 1
4 1580427 Tapered Bead Seal Ring ................................................................................. 1 1
5 161894 Locking Ring.................................................................................................... 1 1
7 STEERING SYSTEM
7 STEERING SYSTEM
UNIT CODE F001
03/2007 EUROPE
SECTION 7
STEERING SYSTEM
DESCRIPTION PAGE
STEERING SYSTEM
FOOTNOTES:
a Service with Horn Replacemet Kit 1642089
b ⇒ D/B 01/2007
c D/B 02/2007 ⇒
FOOTNOTES:
a ⇒ D/B 02/2007
b D/B 02/2007 ⇒
1579908 Seal Kit (Includes Items 1, 8, 16, 21, 28-30, 34) ......................................................... 1
STEERING AXLE
KEY:
A: 5.00 R8 Pneumatic Radial
B: 5.00 x 8-10PR Pneumatic
C: 5.00 x 8 Snap On Tire
D: 18 x 7-8 Snap On Tire
QTY
ITEM PART NO. DESCRIPTION A B C D
8 BRAKE SYSTEM
8 BRAKE SYSTEM
UNIT CODE F001
03/2007 EUROPE
SECTION 8
BRAKE SYSTEM
DESCRIPTION PAGE
BRAKE LINKAGE
SINGLE PEDAL
BRAKE LINKAGE
DUAL PEDAL
BRAKE ASSEMBLY
KEY:
A: Left Hand
B: Right Hand
QTY
ITEM PART NO. DESCRIPTION A B
PARK BRAKE
8-10
UNIT CODE F001
03/2007 EUROPE
9 HYDRAULIC SYSTEM
9 HYDRAULIC SYSTEM
UNIT CODE F001
03/2007 EUROPE
SECTION 9
HYDRAULIC SYSTEM
DESCRIPTION PAGE
9-7
UNIT CODE F001
EUROPE 03/2007
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
HAND LEVERS
THREE FUNCTION
WITHOUT DETENTED LEVERS
1 1578453 Bracket......................................................................................................................... 1
2 1527879 Capscrew..................................................................................................................... 3
3 1583611 Capscrew..................................................................................................................... 2
4 1528327 Pivot Shaft ................................................................................................................... 1
5 1564747 Bushing........................................................................................................................ 6
6 2083701 Hand Lever (Lift) .......................................................................................................... 1
7 2083702 Hand Lever (Tilt) .......................................................................................................... 1
8 2083703 Hand Lever (Auxiliary One) ......................................................................................... 1
9 1517395 Knob ............................................................................................................................ 3
10 1517394 Link .............................................................................................................................. 3
11 309109 Rod End Pin ................................................................................................................ 6
12 1517361 Lock Ring..................................................................................................................... 6
13 1586627 Capscrew..................................................................................................................... 3
14 1346752 Washer ........................................................................................................................ 3
15 2063991 Isolator ......................................................................................................................... 3
16 2064892 Control Valve Assembly (Manual) (☞ Figure 9-10) .................................................... 1
HAND LEVERS
THREE FUNCTION
WITH DETENTED LEVERS
1 1578454 Bracket......................................................................................................................... 1
2 1527879 Capscrew..................................................................................................................... 3
3 230881 Nut ............................................................................................................................... 1
4 197066 Washer ........................................................................................................................ 2
5 1528339 Spacer ......................................................................................................................... 1
6 18086 Capscrew..................................................................................................................... 1
7 1510113 Capscrew..................................................................................................................... 2
8 175861 Spring .......................................................................................................................... 1
9 302428 Pin ............................................................................................................................... 1
10 1542546 Pivot............................................................................................................................. 2
11 1564747 Bushing........................................................................................................................ 10
12 306113 Pin (Selector) ............................................................................................................... 1
13 320161 Washer ........................................................................................................................ 2
14 1528328 Pivot Shaft ................................................................................................................... 1
15 1517361 Lock Ring..................................................................................................................... 6
16 309109 Rod End Pin ................................................................................................................ 6
17 1517394 Link .............................................................................................................................. 3
18 2083706 Hand Lever (Auxiliary One and Two) ........................................................................... 1
19 2083702 Hand Lever (Tilt) .......................................................................................................... 1
20 2083701 Hand Lever (Lift) .......................................................................................................... 1
21 1517395 Knob ............................................................................................................................ 3
22 1586629 Capscrew..................................................................................................................... 3
23 1346752 Washer ........................................................................................................................ 3
24 2063991 Isolator ......................................................................................................................... 3
25 2064892 Control Valve Assembly (Manual) (☞ Figure 9-10) .................................................... 1
HAND LEVERS
FOUR FUNCTION
WITHOUT DETENTED LEVERS
1 1578454 Bracket......................................................................................................................... 1
2 1527879 Capscrew..................................................................................................................... 3
3 1583611 Capscrew..................................................................................................................... 2
4 1528328 Pivot Shaft ................................................................................................................... 1
5 1564747 Bushing........................................................................................................................ 8
6 2083704 Hand Lever (Auxiliary Two) .......................................................................................... 1
7 2083703 Hand Lever (Auxiliary One) ......................................................................................... 1
8 2083702 Hand Lever (Tilt) .......................................................................................................... 1
9 2083701 Hand Lever (Lift) .......................................................................................................... 1
10 1517395 Knob ............................................................................................................................ 4
11 1517394 Link .............................................................................................................................. 4
12 309109 Rod End Pin ................................................................................................................ 8
13 1517361 Lock Ring..................................................................................................................... 8
14 1586627 Capscrew..................................................................................................................... 3
15 1346752 Washer ........................................................................................................................ 3
16 2063991 Isolator ......................................................................................................................... 3
17 2064893 Control Valve Assembly (Manual) (☞ Figure 9-10) .................................................... 1
HAND LEVERS
FOUR FUNCTION
WITH DETENTED LEVERS
1 1578455 Bracket......................................................................................................................... 1
2 1527879 Capscrew..................................................................................................................... 3
3 230881 Nut ............................................................................................................................... 1
4 197066 Washer ........................................................................................................................ 2
5 1528339 Spacer ......................................................................................................................... 1
6 18086 Capscrew..................................................................................................................... 1
7 1583611 Capscrew..................................................................................................................... 2
8 175861 Spring .......................................................................................................................... 1
9 302428 Pin ............................................................................................................................... 1
10 1542546 Pivot............................................................................................................................. 2
11 1564747 Bushing........................................................................................................................ 12
12 306113 Pin (Selector) ............................................................................................................... 1
13 1528329 Pivot Shaft ................................................................................................................... 1
14 320161 Washer ........................................................................................................................ 2
15 1517394 Link .............................................................................................................................. 4
16 1517361 Lock Ring..................................................................................................................... 8
17 309109 Rod End Pin ................................................................................................................ 8
18 2083705 Hand Lever (Auxiliary Two and Three)......................................................................... 1
19 2083703 Hand Lever (Auxiliary One) ......................................................................................... 1
20 2083702 Hand Lever (Tilt) .......................................................................................................... 1
21 2083701 Hand Lever (Lift) .......................................................................................................... 1
22 1517395 Knob ............................................................................................................................ 4
23 1586627 Capscrew..................................................................................................................... 3
24 1346752 Washer ........................................................................................................................ 3
25 2063991 Isolator ......................................................................................................................... 3
26 2064893 Control Valve Assembly (Manual) (☞ Figure 9-10) .................................................... 1
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: 3 Function
B: 4 Function
QTY
ITEM PART NO. DESCRIPTION A B
QTY
ITEM PART NO. DESCRIPTION A B
9-27
UNIT CODE F001
EUROPE 03/2007
TILT SECTION
ELECTRONIC CONTROL
THREE AND FOUR FUNCTION
OUTLET SECTION
ELECTRONIC CONTROL;
THREE AND FOUR FUNCTION
MAST INSTALLATION
TILT CYLINDERS
RIGHT HAND
TILT CYLINDERS
LEFT HAND
9-46
UNIT CODE F001
03/2007 EUROPE
SECTION 10
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE LIMITED FREE-LIFT............................................................................................................... 10-12
HEADER HOSES
TWO STAGE LIMITED FREE-LIFT............................................................................................................... 10-14
INNER MAST
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 10-4
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 10-6
MAIN LIFT CYLINDER
LEFT HAND
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 10-10
RIGHT HAND
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 10-8
OUTER MAST
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 10-2
OUTER MAST
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a Refer to Table
b ⇒ D/B 08/2006
c D/B 08/2006 ⇒
INNER MAST
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a Refer to Table
MAIN LIFT
TWO STAGE LIMITED FREE-LIFT
1 a .. . . . Chain ........................................................................................................................... 2
2 15211 Cotter Pin..................................................................................................................... 2
3 1514866 Pin ............................................................................................................................... 2
4 1369357 Chain Anchor ............................................................................................................... 2
5 297649 Base Ring .................................................................................................................... 2
6 161003 Nut ............................................................................................................................... 2
7 .. . . . Main Lift Cylinder (LH) (☞ Figure 10-5) ..................................................................... 1
8 323160 Washer ........................................................................................................................ 1
9 1481344 Fitting........................................................................................................................... 1
9 252729 O-Ring ..................................................................................................................... 1
9 16485 O-Ring ..................................................................................................................... 1
10 120938 Spring .......................................................................................................................... 1
11 292509 Capscrew..................................................................................................................... 2
12 1379687 Housing (Lowering Control) ......................................................................................... 1
13 1481097 Hose ............................................................................................................................ 2
14 1532650 Fitting........................................................................................................................... 1
14 252729 O-Ring ..................................................................................................................... 1
14 16485 O-Ring ..................................................................................................................... 1
15 313828 Nut ............................................................................................................................... 2
16 1481348 Lowering Control Valve ................................................................................................ 1
16 280154 O-Ring ..................................................................................................................... 1
16 16486 O-Ring ..................................................................................................................... 1
17 1486773 Fitting........................................................................................................................... 1
17 252729 O-Ring ..................................................................................................................... 1
17 16485 O-Ring ..................................................................................................................... 1
18 1487067 Fitting........................................................................................................................... 1
18 252729 O-Ring ..................................................................................................................... 1
18 16485 O-Ring ..................................................................................................................... 1
19 .. . . . Main Lift Cylinder (RH) (☞ Figure 10-4) .................................................................... 1
20 300937 Locknut ........................................................................................................................ 2
21 296422 Washer ........................................................................................................................ 4
22 323090 Spacer ......................................................................................................................... 2
23 292532 Capscrew..................................................................................................................... 2
24 1354915 Washer (0.254 mm) ..................................................................................................... AR
24 1354916 Washer (0.762 mm) ..................................................................................................... AR
24 1354917 Washer (1.524 mm) ..................................................................................................... AR
25 1333382 Washer (1.500 mm) ..................................................................................................... 2
26 131358 Snap Ring.................................................................................................................... 2
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
CARRIAGE
TWO STAGE LIMITED FREE-LIFT
HEADER HOSES
TWO STAGE LIMITED FREE-LIFT
KEY:
A: Three Functions
B: Four Functions
QTY
ITEM PART NO. DESCRIPTION A B
1 a .. . . . Hose .................................................................................................................... 2 4
2 1581582 Capscrew............................................................................................................. 4 8
3 1345348 Clamp .................................................................................................................. 2 4
4 1581566 Nut ....................................................................................................................... 6 6
5 1345412 Bracket (RH) ........................................................................................................ 1 1
5 1345413 Bracket (LH)......................................................................................................... .. 1
6 1477996 Clamp .................................................................................................................. 2 4
7 1481229 Clamp .................................................................................................................. 4 8
8 1360386 Clamp .................................................................................................................. 1 2
9 1581842 Capscrew............................................................................................................. 2 4
10 1345190 Washer ................................................................................................................ 2 4
11 1610939 Bracket................................................................................................................. 1 2
12 1581836 Capscrew............................................................................................................. 2 4
13 1581830 Capscrew............................................................................................................. 1 2
14 1581564 Lockwasher.......................................................................................................... 1 2
15 1360548 Stubshaft ............................................................................................................. 1 2
16 1494017 Sheave................................................................................................................. 1 2
17 1360549 Spacer ................................................................................................................. 1 2
FOOTNOTES:
a Refer to Table
10-16
UNIT CODE F001
03/2007 EUROPE
SECTION 11
MAST-TWO STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-16
FREE LIFT CYLINDER
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-14
FREE-LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-12
HEADER HOSE
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-18
INNER MAST
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-4
MAIN LIFT
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-6
MAIN LIFT CYLINDER
LEFT HAND
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-10
RIGHT HAND
TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-8
OUTER MAST
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-2
OUTER MAST
TWO STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
b ⇒ D/B 08/2006
c D/B 08/2006 ⇒
INNER MAST
TWO STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
MAIN LIFT
TWO STAGE FULL FREE-LIFT
FOOTNOTES:
a ⇒ PENDING PER ECN 10431510
b PENDING PER ECN 10431510 ⇒
FOOTNOTES:
a ⇒ PENDING PER ECN 10431510
b PENDING PER ECN 10431510 ⇒
FREE-LIFT
TWO STAGE FULL FREE-LIFT
1360141 Seal Kit (Includes Items 3-4, 6-10, 12, 16) .................................................................. 1
CARRIAGE
TWO STAGE FULL FREE-LIFT
HEADER HOSE
TWO STAGE FULL FREE-LIFT
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1360507 Clamp .................................................................................................................. 7 9
2 a .. . . . Tube ..................................................................................................................... 1 1
3 a .. . . . Tube ..................................................................................................................... 1 1
4 1360386 Clamp .................................................................................................................. 3 6
5 1581842 Capscrew............................................................................................................. 2 ..
6 1617658 Clamp .................................................................................................................. 2 2
7 1481253 Bracket (RH) ........................................................................................................ 1 1
8 1581849 Nut ....................................................................................................................... 1 1
9 1581592 Capscrew (Lower)................................................................................................ 1 2
10 1581564 Lockwasher.......................................................................................................... 1 2
11 1581560 Washer ................................................................................................................ 2 4
12 1481255 Stub Shaft............................................................................................................ 1 2
13 1581559 Washer ................................................................................................................ .. 1
14 1550020 Spacer ................................................................................................................. .. 1
15 1617657 Clamp .................................................................................................................. 2 4
16 1477996 Clamp .................................................................................................................. 2 4
17 1581741 Capscrew............................................................................................................. 4 8
18 1610914 Bracket................................................................................................................. 1 1
19 1606855 Tube Spacer ........................................................................................................ 2 2
20 1605688 Channel ............................................................................................................... 1 1
21 1345423 Clamp .................................................................................................................. 1 1
22 1360508 Clamp .................................................................................................................. 1 1
23 1581582 Capscrew............................................................................................................. 1 2
24 1481765 Clamp .................................................................................................................. 1 1
25 1581566 Nut ....................................................................................................................... 1 2
26 1481766 Clamp .................................................................................................................. .. 1
27 1529015 Cap ...................................................................................................................... 2 4
28 137852 Strap Clamp......................................................................................................... 1 2
29 a .. . . . Channel ............................................................................................................... 1 1
30 1581830 Capscrew (Upper RH) ......................................................................................... 1 ..
30 1597560 Capscrew (Upper LH) .......................................................................................... .. 1
©2007 HYSTER COMPANY See Service Manual 11-19
for service procedures.
UNIT CODE F001
EUROPE 03/2007
HEADER HOSE
TWO STAGE FULL FREE-LIFT
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Table
SECTION 12
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-20
FREE-LIFT
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-16
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-18
HEADER HOSE
THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-22
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-6
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-4
MAIN LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-8
MAIN LIFT CYLINDER
LEFT HAND
THREE STAGE FULL FREE-LIFT ............................................................................................................ 12-14
RIGHT HAND
THREE STAGE FULL FREE-LIFT ............................................................................................................ 12-12
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-2
OUTER MAST
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
b ⇒ D/B 08/2006
c D/B 08/2006 ⇒
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
INNER MAST
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
MAIN LIFT
THREE STAGE FULL FREE-LIFT
1 a .. . . . Chain ........................................................................................................................... 2
2 15211 Cotter Pin..................................................................................................................... 4
3 1514866 Pin ............................................................................................................................... 4
4 1369357 Chain Anchor ............................................................................................................... 2
5 297649 Base Ring .................................................................................................................... 4
6 161003 Nut ............................................................................................................................... 4
7 1365140 Chain Anchor ............................................................................................................... 2
8 15223 Cotter Pin..................................................................................................................... 2
9 .. . . . Main Lift Cylinder (LH) (☞ Figure 12-6) ..................................................................... 1
10 323160 Washer ........................................................................................................................ 1
11 120938 Spring .......................................................................................................................... 1
12 1481344 Fitting........................................................................................................................... 1
12 16485 O-Ring ..................................................................................................................... 1
12 252729 O-Ring ..................................................................................................................... 1
13 252729 O-Ring ..................................................................................................................... 1
13 1532650 Fitting........................................................................................................................... 1
13 16485 O-Ring ..................................................................................................................... 1
14 1481097 Hose ............................................................................................................................ 2
15 1486773 Fitting........................................................................................................................... 1
15 252729 O-Ring ......................................................................................................................... 1
16 1481348 Lowering Control Valve ................................................................................................ 1
17 313828 Nut ............................................................................................................................... 4
18 1333392 Housing ....................................................................................................................... 1
19 1473898 Fitting........................................................................................................................... 1
19 16486 O-Ring ..................................................................................................................... 1
20 292509 Capscrew..................................................................................................................... 2
21 1487067 Fitting........................................................................................................................... 1
21 16485 O-Ring ..................................................................................................................... 1
21 252729 O-Ring ..................................................................................................................... 1
22 .. . . . Main Lift Cylinder (RH) (☞ Figure 12-5) .................................................................... 1
23 1581849 Nut ............................................................................................................................... 2
24 1581852 Washer ........................................................................................................................ 4
25 323090 Spacer ......................................................................................................................... 2
26 1581829 Capscrew..................................................................................................................... 2
27 1354915 Washer (0.254 mm) .................................................................................................... AR
27 1354917 Washer (1.524 mm) .................................................................................................... AR
27 1354916 Washer (0.762 mm) .................................................................................................... AR
28 1333382 Washer (1.500 mm) ..................................................................................................... 2
29 131358 Snap Ring.................................................................................................................... 3
30 1581580 Capscrew..................................................................................................................... 4
MAIN LIFT
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
12-11
UNIT CODE F001
EUROPE 03/2007
FOOTNOTES:
a Refer to Table
FOOTNOTES:
a Refer to Table
FREE-LIFT
THREE STAGE FULL FREE-LIFT
1 a .. . . . Hose ............................................................................................................................ 1
2 a .. . . . Chain ........................................................................................................................... 1
3 1343989 Hose Sheave ............................................................................................................... 1
3 1354901 Bushing ................................................................................................................... 1
4 1360534 Stubshaft ..................................................................................................................... 1
5 1581564 Lockwasher.................................................................................................................. 1
6 1581829 Capscrew..................................................................................................................... 1
7 1481054 Chain Sheave Assembly.............................................................................................. 1
7 1378699 Bearing .................................................................................................................... 2
8 1596406 Capscrew..................................................................................................................... 1
9 1596407 Lockwasher.................................................................................................................. 1
10 1596408 Washer ........................................................................................................................ 1
11 1481055 Chain Guard ................................................................................................................ 1
12 1581849 Nut ............................................................................................................................... 1
13 1581591 Capscrew..................................................................................................................... 1
14 1481230 Capscrew..................................................................................................................... 1
15 1581562 Washer ........................................................................................................................ 1
16 1481052 Crosshead Pin ............................................................................................................. 1
17 310549 Pin ............................................................................................................................... 1
18 1481009 Crosshead ................................................................................................................... 1
19 1489972 Guard........................................................................................................................... 1
20 1596404 Lockwasher.................................................................................................................. 4
21 1581852 Washer ........................................................................................................................ 4
22 1581849 Nut ............................................................................................................................... 4
23 .. . . . Free-Lift Cylinder (☞ Figure 12-8) ............................................................................. 1
24 1573677 Guard........................................................................................................................... 1
25 1481346 Flow Valve ................................................................................................................... 1
26 182377 Nut ............................................................................................................................... 1
27 182376 Base Ring .................................................................................................................... 1
28 1514866 Pin ............................................................................................................................... 1
29 1605676 Chain Anchor ............................................................................................................... 1
30 15211 Cotter Pin..................................................................................................................... 1
FOOTNOTES:
a Refer to Table
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
1360141 Seal Kit (Includes Items 3-4, 6-10, 12, 16) .................................................................. 1
FOOTNOTES:
a Refer to Table
CARRIAGE
THREE STAGE FULL FREE-LIFT
HEADER HOSE
THREE STAGE FULL FREE-LIFT
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1360549 Spacer ................................................................................................................. 1 2
2 1345190 Washer ................................................................................................................ 1 2
3 1581830 Capscrew............................................................................................................. 2 2
4 1550020 Spacer ................................................................................................................. .. 1
5 1598303 Washer ................................................................................................................ .. 1
6 1481255 Stub Shaft............................................................................................................ 1 2
7 1481253 Bracket (RH) ........................................................................................................ 1 1
8 1581849 Nut ....................................................................................................................... 2 4
9 1581564 Lockwasher.......................................................................................................... 1 2
10 1581592 Capscrew............................................................................................................. 1 2
11 1581560 Washer ................................................................................................................ 2 4
12 1477996 Clamp .................................................................................................................. 3 6
13 1617657 Clamp .................................................................................................................. 3 6
14 a .. . . . Hose .................................................................................................................... 1 2
15 a .. . . . Hose .................................................................................................................... 1 2
16 1360507 Clamp .................................................................................................................. 2 2
17 1610914 Bracket................................................................................................................. 1 1
18 1581841 Capscrew............................................................................................................. 2 4
19 1360386 Clamp .................................................................................................................. 2 4
20 1581842 Capscrew............................................................................................................. 2 4
21 1597565 Capscrew............................................................................................................. 1 2
22 1363253 Bracket................................................................................................................. 1 2
23 1348247 Hose Guide.......................................................................................................... 1 1
24 1581558 Washer ................................................................................................................ 2 4
25 1581567 Nut ....................................................................................................................... 1 2
26 1348246 Hose Guide.......................................................................................................... .. 1
27 1581566 Nut ....................................................................................................................... 3 6
28 1481765 Clamp .................................................................................................................. 1 1
29 1481766 Clamp .................................................................................................................. .. 1
30 1581582 Capscrew............................................................................................................. 1 2
31 1529015 Cap ...................................................................................................................... 2 4
32 1481249 Hose Sheave ....................................................................................................... 1 2
32 1353521 Bushing ........................................................................................................... 1 1
33 1481252 Bracket (LH)......................................................................................................... .. 1
34 1581559 Washer ................................................................................................................ 1 2
35 1381598 Bracket................................................................................................................. 1 1
35 1381599 Bracket................................................................................................................. .. 1
HEADER HOSE
THREE STAGE FULL FREE-LIFT
QTY
ITEM PART NO. DESCRIPTION A B
36 1581836 Capscrew............................................................................................................. 2 4
37 1381642 Stub Shaft............................................................................................................ 1 1
37 1381641 Stub Shaft............................................................................................................ .. 1
38 1494017 Sheave................................................................................................................. 1 2
39 1481248 Hose Sheave ....................................................................................................... 1 2
39 1353521 Bushing ........................................................................................................... 1 1
40 1597560 Capscrew............................................................................................................. 1 1
FOOTNOTES:
a Refer to Table
13 OPTIONS
13 OPTIONS
UNIT CODE F001
03/2007 EUROPE
SECTION 13
OPTIONS
DESCRIPTION PAGE
STROBE LIGHT
(⇒PENDING PER ECN 10298201)
BACK-UP ALARM
FOOTNOTES:
a ⇒ S/N F001V01720D
b S/N F001V01721D ⇒
FOOTNOTES:
a ⇒ S/N F001V01720D
b S/N F001V01721D ⇒
13-9
UNIT CODE F001
EUROPE 03/2007
ACCUMULATOR
1 1465897 Accumulator................................................................................................................. 1
2 1609864 Spacer ......................................................................................................................... 2
3 1611564 Clamp .......................................................................................................................... 2
4 2073766 Hose ............................................................................................................................ 1
5 2086635 Hose ............................................................................................................................ 1
6 1487096 Fitting........................................................................................................................... 1
6 252729 O-Ring ..................................................................................................................... 3
KEY:
A: Two Stage Full Free-Lift
B: Three Stage Full Free-Lift
QTY
ITEM PART NO. DESCRIPTION A B
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Integrated Side-Shift
b Standard Side-Shift
KEY:
A: Three Function, Left Hand Side
B: Four Function, Right Hand Side
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Integrated Side-Shift
b Quick Disconnect Option
c Right Hand Side for Four Function not shown
d Standard Side-Shift
13-24
UNIT CODE F001
03/2007 EUROPE
14 NUMERICAL INDEX
UNIT CODE F001
03/2007 EUROPE
SECTION 14
NUMERICAL INDEX
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
126 3-41 25 6-3 14 3-19 39 55407 10-9 11
3-43 12 16168 3-15 33 3-21 39 10-11 11
206 8-5 23 16199 3-15 34 3-30 51 11-9 7
12929 8-5 24 16480 9-29 13 16865 3-46 14 11-11 7
13957 7-9 12 16481 5-35 3 16983 5-28 46 12-13 11
14191 7-10 4 9-6 3 16984 9-3 13 12-15 11
14385 2-9 16 16483 5-27 14 17353 3-15 18 57664 9-43 2
2-11 15 13-17 4 17650 3-35 3 9-45 2
2-45 15 13-19 4 18086 9-13 6 58901 10-3 6
2-47 15 13-21 15 9-17 6 10-5 4
14591 9-3 21 13-23 13 18497 1-49 8 10-13 3
9-6 3 16484 5-15 46 1-57 11 11-3 6
15135 5-9 11 5-25 19 18515 1-49 10 11-5 4
5-15 11 5-27 5 1-57 12 11-17 3
5-25 9 9-9 2 18595 5-9 9 12-3 6
15158 5-9 10 11-13 32 5-15 9 12-5 7
5-15 10 16485 5-4 7 18596 5-25 7 12-7 4
5-25 8 5-4 8 18832 13-13 10 12-21 3
15200 10-13 11 5-7 5 13-15 10 13-13 14
15211 10-7 2 5-7 7 21420 6-3 15 13-15 21
11-13 23 5-9 5 34507 3-19 36 58903 7-9 2
11-17 11 5-15 5 3-21 36 58916 5-9 23
12-9 2 5-15 40 3-23 19 5-15 24
12-17 30 5-25 25 3-25 2 5-27 34
12-21 11 5-27 9 3-29 2 63108 3-15 15
13-13 21 10-7 9 3-33 31 68968 2-13 7
13-15 17 10-7 14 37752 12-5 12 2-15 7
15223 12-9 8 10-7 17 39352 7-9 6 2-17 8
15241 6-3 31 10-7 18 39374 9-43 9 2-19 6
15245 7-9 18 11-7 3 9-45 9 2-49 8
15931 3-46 9 11-7 8 43207 5-13 17 2-51 16
15971 3-15 42 11-7 10 5-18 18 2-53 4
16001 10-3 10 11-7 11 5-21 22 77442 9-21 3
11-3 10 11-7 12 5-23 22 9-23 7
12-3 10 11-13 17 5-25 21 9-31 3
16040 9-43 16 12-9 12 5-31 21 9-35 4
9-45 16 12-9 13 5-33 21 9-37 4
16041 9-41 10 12-9 21 43208 5-9 19 77443 9-21 5
13-13 12 16486 5-15 42 5-15 20 9-23 8
13-15 12 5-15 44 5-25 14 9-31 4
16079 4-11 9 10-7 16 44307 5-13 19 9-35 5
4-15 29 12-9 19 5-18 20 9-37 5
4-15 30 16540 13-21 15 5-27 10 86229 5-9 18
16134 3-15 4 13-23 13 44308 5-9 24 5-15 19
3-16 44 16682 5-9 30 5-15 25 5-25 10
3-19 18 5-15 32 5-27 32 87446 3-35 4
3-21 18 5-27 24 44310 5-9 33 88441 12-9 1
3-23 32 16706 9-21 6 5-15 35 97999 3-15 5
3-29 46 9-23 3 5-27 19 3-19 41
3-30 51 16708 3-46 7 53162 3-46 13 3-21 41
3-33 39 16788 3-15 16 55146 11-15 7 3-29 49
16151 3-35 6 16863 3-16 44 12-19 7 98525 7-9 24
©2007 HYSTER COMPANY See Service Manual 14-1
for service procedures.
UNIT CODE F001
EUROPE 03/2007
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM