PARTS MANUAL ELECTRICs J1.60-2.00XMT (G160) Customer Edition 1453953 PRINTED INENGLAND BY XEROX BUSINESS SERVICES 09197SERIAL CODE G160-EUR. HYSTER MAINTENANCE PARTS QUICK REFERENCE LIST CONTACTORS TYPE CONTACTOR ‘STATIONARY MOVING SPRING | Pump (Single Speed) 300184 = Figure 50 1300278 271695, Pump (Two Speed) 2908760 7 Figure 31 2013602 271887 Steering 2910152 7 Figure 34 = "1945909 Line 1458551 e Figure 88 1900278 271893 BRUSHES AND SPRINGS ‘STANDARD. PREMIUM "Traction Motor 2308091 2309573 Brush 2308510 2308516 Spring 230854 2308054 Steering Motor 2084301 2084300 Brush) 7190172, 1452885 ‘Spring "1909578 1909878 Hydraulic Motor (1200) 2038428 2052429 Brush 2026351 (4) 2026951 (2)/2026952 (@) ‘Spring 2018456 2013456 ] PERIODIC MAINTENANCE AEROSOLS Hydraulic Fiter a Electric Motor Cleaner ‘3066000 "Tank Filler 1802007 Slicone Spray SOATEBD Tnline Fiter 2800276 Thain Labo oa es 1302665 Paint Yellow 1845800 IGNITION SWITCH Key FUSES BATTERY CONNECTOR oO Amp rr ‘SBE Gray 378381 325 Amp [325809 SBE Biue 376383 ao Amp 1304082 DIN Black (2031026 [samp 1453532 (©1997 HYSTER COMPANY See Service Manual {for service procedures enis7HYSTER sea coe avn etn NOTES (©1967 HYSTER COMPANY See Service Manual en/97 for service proceduressera gent ove. an HYSTER ILLUSTRATED CONTENTS REE SECTION PAGE 1 FRAME .... «Page 3 2 DRIVE AXLE . Page 15 3 STEERING . » Page 25 4 BRAKE . . Page 35 5 ELECTRICAL » Page 47 6 HYDRAULIC .... » Page 69 7 TWO STAGE LIMITED FREE LIFT Page 85 8 ‘THREE STAGE FULL FREE LIFT . Page 101 9 TWO STAGE FULL FREE LIFT . Page 121 40 OPTIONAL EQUIPMENT Page 141 ©1907 HYSTER COMPANY See Service Manual en97 for service proceduresHYSTER sen cone ou. sin TABLE OF CONTENTS DESCRIPTION a A ‘Accelerator Pedal... : B Backup Alarm .. + Page 154 Battery Connector .....cscsseseeeeserseneesecssseterecssreeseseerens Page 67 Brake ASSY o. ee ceeeeeeeeseeereee 7 + Page 48, Brake Master Cylinder .......ccscescecseeseseesseeeeeeesseseseee ++» Page 40 Brake Pedal Linkage ........ See sieeeeeeesenes Page 88 c Cartage Three Stage Full Free Lift ...... ‘i -. Page 112 Carriage ‘Two Stage Full Free Lif .........++ re - Page 146, Carriage ‘TWo Stage Limited Free Lift ......sssssceeeseesesesessseessenesess Page 92 Contactor Panel .... -- Page 56 Contactor Panel Power Steering and Line ....... Contactor Panel ‘Two-speed Pump... Control Valve . Counterweight ....... Cow! Electrical, Front... Cow! Electrical, Rear Cylinder ‘Two Stage Limited Free Lift .........6.6+5 (©1997 HYSTER COMPANY ‘See Service Manual enis7 {for service procedures:sen coorcoan HYSTER TABLE OF CONTENTS DESCRIPTION PAGE E Electrical System Contactor Hydraulics . eae Page 48 Electrical System Single Speed Pump seseeeesens Page 52 Electrical System ‘Two-speed Pump .. fetetetenenserseses Page 60 Floomplates And Covers ....... Page 4 For rk ‘Three Stage Full Free Lift... Page 120 Fork ‘Two Stage Full Free Lift .... 7 ++ Page 154 Fork ‘Two Stage Limited Free Lift . Siaeeuarseuataaree = Page 100 Free-it ‘Three Stage Full Foo Lift .......ssscecssesveee cesses Page 108 Free-lit Two Stage Full Free Lift «2.2... Page 140 Freecit Cylinder Three Stage Full Froe Lift ........secsceceseees + Page 110 Free-titt Cylinder Two Stage Full Free Lift... sees «Page 144 FOOMLIQHS ....ssessceesvessesesesescseseseees + Page 146 H Hand Pump ...+..es0 Header Hose ‘Attaching Parts ‘Three Stage Full Free Lift ... veseeees Page 116 Header Hose Attaching Parts Two Stage Full Free Lift ....eeseeeee Page 150 (©1997 HYSTER COMPANY See Service Manual e/97 for service proceduresHYSTER sen cove aun evn TABLE OF CONTENTS q H (CONTINUED) Header Hose ‘Attaching Parts ‘Two Stage Limited Free Lift seseeeeeeses Page 96 Header Hose ‘Three Stage Full Free Lift . - Page 118 Header Hose ‘Two Stage Full Free Lif : ceeteeeseeseseeseees Page 152 Header Hose Two Stage Limited Free Lit . seiseseeterseneenees Page 88 Hydraulic Motor ....seseseeseneeseetseterseteeeerserees - Page 78 Hydraulic Pump .. seceensenees Page 77 Hydraulic System ... - Page 62 1 Innerfintermediate/Outer Mast ‘Three Stage Full Free Lift. Inner/Outer Mast ‘TWo Stage Full Free Lift ......ceseseeseeeseeeeeees Inner/Outer Mast ‘Two Stage Limited Free Lift .......... -. Page 86 Instrument Panel ae -» Page 65 L Labels & Paint ....... ++ Page 12 Litt ‘Two Stage Limited Free Lift ....esseeeeseeeeee ++ Page 68 Lighting System .....sseeeereeeeee 7 cesses Page 144 Line Contactor ... sieesetersenseses Page 61 Load Backrest Extension ‘Three Stage Full Free Lift ee - Page 118 (©1007 HYSTER COMPANY See Service Manual erig7 {for service proceduresssn. cope cue cn HYSTER TABLE OF CONTENTS Hamel L (CONTINUED) Load Backrest Extension “Two Stage Full Free Lift + Page 147 Load Backrest Extension ‘Two Stage Limited Free Lift ... +++ Page 93 uM Main Cylinder ‘Three Stage Full Free Lift .... -++ Page 108 Main Cylinder ‘Two Stage Full Free Lift ...... Main Lit ‘Three Stage Full Free Lift Main Lift ‘Two Stage Full Free Lift .. Reeeateaae - Page 198 Master Drive Unit .........ses+6 ae + Page 16 Motor Cooling Fan........+. - Page 156 N Non-Suspension Seat ......eseesseses secseeeee Page 9 ° Overhead Guard ....... » Page 7 P Park Brake . » Page 44 Park Brake Linkage .... See - Page 42, Power Converter Se . Page 168 Pump Contactor Ingle-Speed PUMP ....seseeseeseeeeees seve Page 57 Pump Contactor ‘Two-Speed Pump Page 58 ©1907 HYSTER COMPANY ‘See Service Manual enio7 for service proceduresu HYSTER sstin.co0e een um TABLE OF CONTENTS DESCRIPTION a Rear Light ......... - Page 147 Shift Lever...... - Page 66 Sideshift Carriage .. chee etesiseeeseeseeerseesseneess Page 142, Sideshift Cylinder ‘Group No. 8601901 ....... peat eee ee » Page 143, Spotlight ........ - Page 155 Steering Contactor . peseetenseeveeesss Page 62 Steering Motor (Premium) . - Page 34 Steering Motor (Standard) . - Page 33 Siocting od settaiiimianamvet ee enantio t te scPage 6 Steering Pump ... - Page 32 Steering Tyre & Wheel .. - Page 161 Strobe Light High Mount... ++. sees eeeeeesenees ees Page 148 Suspension Seat .......++ Page 10 Tall Light 2... .csecseeceeseecesseceeetseeseesseeees Tilt Cylinder Tilt Cylinder Attaching Parts 1'00 Stage Full Froe Lift .......sseeseeessesseseesaseseeereaesees Page 114 Tilt Cylinder Attaching Parts fwo Stage Full Free Lift .........++6 - Page 148, (©1997 HYSTER COMPANY See Service Manual 6/97 for service proceduressen cooreman HYSTER TABLE OF CONTENTS DESCRIPTION, ip T (CONTINUED) Tit Cyingor Attaching Parts fwo Stage Limited Free Lift .... ‘Traction Motor Premium ......6..00+5 ‘Traction Motor ‘Standard .. Trail Axle... ‘Transmission ‘Tyre & Wheel Dire Sates ee seared eS eee ete Cee eee eee Eg Page 159 v Valve Attaching Parts .......4 seeeseeees Page 72 (©1997 HYSTER COMPANY Seo Service Manual enor for service proceduresHYSTER enn coveoree an HOW TO USE ILLUSTRATED PARTS MANUAL ‘This parts manual describes and illustrates assemblies, The different constructions are indicated by keys, sym- subassemblies, and detail parts needed for service re-_bols and footnotes. placement. CARRIAGE (Figure 123) st USED ON SIN PENDING PER EGN 98765 1 3 6 8 7 a ° cy x \ ‘ 2 @ 1997 HYSTER COMPANY See Service Manual eHis7 for service proceduresssn cone ato-svn __ HYSTER HOW TO FIND THE DESIRED PART NUMBER WHEN THE PART NUMBER AND THE NEXT GENERAL: Ucaniteeesememerecteereecebiceniaae ‘The assembly breakdowns include part numbers, ‘1, Determine the function and application of the partre- description, quantities required, keys and footnotes uired. Turn to the illustrated index page immediate- to help in selecting the correct parts. ly behind the front cover. Choose the general area of z reference most likely to include the part. 6. Keys are used to show effective serial numbers for two or more similar assemblies, RH and LH assem- bly patts, etc. select the appropriate key, "A", "8", °C" oD" and the corresponding quantity column to find the required parts. 2. Find the page number for the reference number you ‘choose and turn to that page. Use the division index to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page. 7. Indented descriptions under"Name of Part” are used {oindicate assemblies and sub-paris of assemblies. ee PARTE Oren are Inthe example (Item 7), LOAD ROLLERIs a subpart THE NEXT HIGHER ASSEMBLY IS KNOWN: of the major assembly CARRIAGE. 8. Determine the assembly the required partis usedon. ‘Tum to the Table of Contents immediately following the illustrated Contents. 8. Quantities shown are for one assembly. Note that two assemblies are shown, but the quantities of the subparts are indicated as three and three. This 4. Locate the assembly the required partis usedonand meane three per assambly. turnto the page indicated for that assembly. Then fo- cate the part on the assembly breakdown page. 9, Engineering change notice (ECN) numbers for pending serial numbers are shown to allow forthe in- WHEN THE PART NUMBER IS KNOWN: clusion of the most current parts information. Con- 5, Use the numerical index at the back of the manual to. tact your local dealer for Hyster lift trucks for serial find the part number. Turn to the figure listed and lo- ‘number information listed by ECN number. cate the part as indicated by the reference number, 49, Aduitonal fork tengths are available. Contact your dealer for Hyster lft trucks. ORDERING PARTS: ‘When ordering replacement parts, give the unit serial number, part number, name of part and quantity required. For any further information on parts, service, or ordering, consult your local dealer for Hyster lift trucks. (©1997 HYSTER COMPANY See Service Manual eiis7 for service proceduresHYSTER ssvn.cobe 10-EUR IDENTIFICATION OF TRUCK SERIAL NUMBERS fT itd (1) & (2) The first letter and three numbers indicates the truck model code. (3) The second ietter indicates the plant of manufacture. (4) The four or five digit number series indicates the serial number of the truck. (©) The final letter indicates the year of manufacture starting with "A" in 1987 and 1980, The letters “I”, “O", and “Q" will not be used. For pending serial numbers contact your local dealer for Hyster lit trucks. ‘Truck Serial Number Printed on Nameplate RH SIDE LH SIDE Truck Serial Number i] Stamped on Frame Parts referred to in this book as right or left hand parts are in accordance with the illustration above. (©1807 KYSTER COMPANY See Service Manual enti97 for service proceduressx. cor roni HYSTER IDENTIFICATION OF MAST SERIAL NUMBERS a (1) & (2) The firs letter and number indicates the mast model code. (@) The second letter indicates the plant of manufacture. (4) The four or five digit number series indicates the serial number of the mast. (8) __Lift Height in milimeters stamped just below the serial number Mast Group Identification consists of mast unit code (1) & (2) plus lift height (5). For pending serial numbers contact your local dealer for Hyster lit trucks, LIFT EQUIPMENT IDENTIFICATION Fork part number, capacity rating, plant code letter and date of manufacture are stamped 1, approximately six inches below the top of most forks. 2. The carriage group number is stamped on the i, right hand side of the top cross member (pin it type) or on the back of the right hand end of the bottom crosmemberthook ype) A date FE code has two letters inline with or below the (| 3 carriage group number. 8, The mast identification number has a model code, a letter indicating the plant of manufacture, and a serial number. Underneath the serial number is a four digit number that indicates the total lit height for the mast in millimetres. 3. 4. Tilt and ltt cylinder group numbers are stamped on the cylinder shell. Always refer to the group, serial or part 2 number when ordering service parts. Modification of masts and carriages by SPED (Special Products Engineering Department) are Identified by a mode! prefix code beginning with the letter “S", Contact your dealer for Hyster lift trucks for information on these assemblies, (©1997 HYSTER COMPANY ‘See Service Manual enis7 for service procedures:HYSTER erin cob aie-cun IDENTIFICATION OF ATTACHMENT AND SIDE-SHIFT CARRIAGE SERIAL NUMBERS DELT (1) & 2) The first letter and three numbers indicates the attachment model code. (8) The second letter indicates the plant of manufacture. (4) The tour or five digit number series indicates the serial number. For pending serial numbers contact your local dealer for Hyster it trucks. NAMEPLATE, ‘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. Modification of attachments and side-shift carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the lelter “S". Contact your dealer for Hyster lift trucks for information on these assemblies. (©1997 HYSTER COMPANY See Sorvice Manual enis7 for service procedures,Page 1 SERIAL CODE G160-EUR HYSTER MAINTENANCE PARTS QUICK REFERENCE LIST (Figure 1) CONTACTORS TYPE CONTACTOR STATIONARY MOVING ‘SPRING Pump (Single Speed) 380184 er Figure 30 1300278 271893. Pump (Two Speed) 2308760 i Figure 31 2013602, 271887 Steering 2310152 ex Figure 34 cas 1345909 ine 1453551 > Figure 33 3300276 271800 BRUSHES AND SPRINGS STANDARD PREMIUT ‘Traction Motor 2309091 2309573 Brush 2308510 2308516 Spring 2308954 2308954 ‘Steering Motor 2034301 2034300 Brush 1391772, 1452885 So est isos Hydraulic Motor (12cc) 2032428 2032429 Brush 2026351 (4) 2026351 (2)/2026352 (2) Spring 2013456 2013466 PERIODIC MAINTENANCE AEROSOLS Hydraulic Fiter ; ‘Tank Filter Inline Fitter Breather Electric Motor Cleaner Silicone Spray ‘3066000 3041620 Chain Lube 4171850 Paint Yellow IGNITION SWITCH Key 1337197, BATTERY CONNECTOR ‘SBE Gray 378361 ‘SBE Blue 378383, DIN Black [2031026 (©1997 HYSTER COMPANY ‘See Service Manual for service procedures 6/97HYSTER Page 2 SERIAL CODE G160-EUR PUBLICATIONS (Figure 2) For overy Hystor tuck at tast three publications are avaiatte, Th publications aro tho Parts Manus, Uo Operating Manual and ho Sorviea Manual ‘Tho OPERATING MANUAL must slays be availble on every it ruck. ‘This manval has iformatlon thal the eperalor must know fr inspection and operation ofthe ft wack. ‘roviiig the repair and adstment procedures of adilecent component ‘or syslom. Each SAM secton can be ovdarad separately os wel, “These manuals, othor pubcations and programs are avaiable trom your Dealer or Hystor Lit Tucks to halp you operate and maintain your it truck professtanaly. Sao the lsthere below errtaronco to ho publealons SERVICE MANUAL consis of SRM sectons cach doscbing or concerning to It ck model ae Gescibed in ie PARTS MANUAL. ‘Operating Manual ‘Standare/50 fr _| Premiurn/600 he English 1485897 1453044 Fronoh 7485880 7450846 German 1455900 "1453047 ‘Spanish 1486008 71453060 Talian 1455901 7483048 Dutch 7485896 71453985 Danish 1455805 450042 Portuguese 1455902 "1459840 Swedish 1455000 71459057 Finnish 77455896 159045 [Service Manual (Gormplete) Frame (100 SRM 588) 397780 DG Motor Maintenance (620 SAM 294) 07076 “Transaxle (1300 SRM 668) 1397656 Sieeting System (1600 SANA 687) 1483608 ‘Sieoring Control Unit (1600 SAM 672) 297408 Brake System (1800 SAM 655) 987983 Main Gonirol Valve (2000 SRM 676) 897671 Til Cylinders (2100 SRM 103) 10102 SXISR Transistor Motor Contvolar (2200 SRM 697) "454688 Electrical System (2200 SAM 698) 1454565 industrial Battery (2240 SRM 1) 390648 Mast (4000 SAM 521) 897608 Mast-Repair (4000 SAM S23) 397602 Periodic Maintenance (6000 SAM 584) 1454500 Pais vanioe Gn | Diagrams (6000 SRM 696) | Capacities and Speciications (6000 SAM 586) 89778 Tach (SAE) and Metric Fasteners (8000 SRM 231) 310842 Parts Manual English 459055 German 1453956 ‘Spanish “1459868 French 1459955 Tata 71459087 Dutch 7459952 Finnish (OK) 71453080 Portuguese (SP) 1450966 ‘Swedish (UK) 71453963 Danish (UK) “1459969 ©1997 HYSTER COMPANY See Service Manual eitl97 for service proceduressera. gose een HYSTER FRAME COUNTERWEIGHT ......... : fe + Page 8 FLOORPLATES AND COVERS .. + Page 4 LABELS & PAINT .. « Page 12 NON-SUSPENSION SEAT . + Page 9 OVERHEAD GUARD .. . Page7 SUSPENSION SEAT 0. .scsccseeeseees cceeeeseeeesesereess Page 10 1807 HvSTER COMPANY ‘See Service Manual eis7 tor service proceduresHYSTER serum cove 100-2 FLOORPLATES AND COVERS (Figure 3) (©1997 HYSTER COMPANY See Service Manual en/a7 for service proceduresPage 5 HYSTER SERIAL CODE G160-EUR. FLOORPLATES AND COVERS Key ‘A: 1495 mm Wheelbase B: 1385 mm Wheelbase aly aty Ret__Part No, Name Of Part AB Bet PartNo, Name Of Part AB 1 2909936 Stud Wheelbase ............1 1 44 296252 Hex Head Bolt 44 2 15026 Nut Wheelbase set 1 45 2013630 Pivot (LH) 11 3 2909977 Bush Wheelbase 11 45 2019629 Pivot (RH) oes eeeeeceee Td 4 16634 HexHead Bolt Wheclbase ....1 1 46267881 HexHead Boll... secs... dd 5 15187 Washer ...ceccececceseeseee 1 1 47 292681 Lockwasher A 6 18176 Washer .. 22 4B 201BGEBT Bracket ee sseseeeeeeerereee 2 2 7 196749 Hex Head Bolt : 22 49 2311598 Screw... eee 22 8 820187 Washer .s.eceeeccrereseees 4 4 50 15176 Washer 22 9 292681 Lockwasher . 22 51 2C9BOO NUL seeeressererserrereneee 2 2 10 289503 Nut ..... 22 52 26283 Grommet . 1 11 2811028 Latch Assy 11 53 261158 Strip 12 19981 PIN seeeseesseeeeseesseeee 1 1 54 2032006 Frame . 13 2905088 Pin -11 © 84 — 2032007 Frame ..... : 44 2307799 Spring . 11 55 2019642 Cover Assy . 15 2305209 Guide ... 41 56 2014534 Knob . 16 296168 Hex Head Bolt . 55 57 15086 Nut... 17 920158 Washer ......seesevee 010 58104718 Grommet... 18 292681 Lockwasher .. 5.5 59 2019636 TowPin ..... 19 292654 Nut .. +6 8 60 2013847 Retainer..... 20 292602 Hex Head Bolt .. .22 61 293603 HexHead Bolt ........ 21 820156 Washer . +22 62 * 292680 Lockwasher .......++ 22 292680 Lockwasher ............41.2 2 63 296417 Washer 23° 136687 Nut (44° 64 186687 Nut. 24 962030 Handle 11 65 289250 SHD se eeeeeeeereeees 25 2910622 Plate...... -14 66 2013646 Strip : 26 298796 Hex Head Bolt . 22 67 2018644 Strip... eee 27 292680 Lockwasher ....sssessssses,2 2 68 2019576 Cover. : 28 136687 Nut .. +22 69 2039783 Floorplate, RH. «+++ 28 362030 Handle 11 70 2083076 Floorplate, LH. . 30 15223 Pin -22 70 ® 878803 Floorplate, LH. 81 920158 Washer . +66 71 376947 Frame . 92 292654 Nut : +22 72 2013955 Cowl Cover (Top) ...... 83 292681 Lockwasher ... 22 73 2907691 Cowl Cover rent) 34 2081198 Cylinder . 22 74 — 802047 Sorew.......-.- 35 261164 Joint .. teeseeeseed 1 75 920156 Washer . 36 2019604 Battery Cover vss vssessese Tw 78 198687 Nut 36 2032486 Battery Cover .... seu 1 77 2038186 Frame ... 87 2311460 Wire Harness .... -11 77 2088187 Frame . 38 197852 Ty-Wrap .. +32 78 2033110 Floor Mat. 38 136749 Hex Head Bolt . -44 79 279737 Grommet ..... 40 282681 Lockwasher . +44 80 261158 Strip M1 820158 Washer vecsceecececeerene 8 8 BT 16458 Fitting .. 42 2019627 Hinge (LH) S11 82 2052989 COW... reeseeeereeeene 42 2013626 Hinge (RH) +1183 292515 Hex Head Bolt ......0.05 43 2810972 Bearing 2 "84 320159 Washer . ©1097 HYSTER COMPANY ‘See Service Manual ene7 for service procedures:HYSTER sen co9eonngin FLOORPLATES AND COVERS (CONTINUED) key ‘A; 1495 mm Wheelbase B: 1985 mm Wheelbase 85 2307638 Nut 22 90 2302061 Stud 122 86 2309317 Pad -1 4 90 186687 Nut . 22 87 2014993 Nut 22 90 320156 Washer ... 122 88 2015005. Side Plate (LH) 1 91 2094115 Trim 122 wad 88 — 2082103 Side Plate (LH)......cesecse 1 92 2084116 Trim 89 2014981 Side Plate (RH) 89 2014980 Side Plate (RH) - 1 Used with Motor Cooling Fan Option (©1907 HYSTER COMPANY ‘See Service Manual en97 for service proceduressen cooe 8 HYSTER OVERHEAD GUARD (Figure 4) key A: 1495 mm Wheelbase B; 185 mm Wheelbase ty aty 1 2038026 Overhead Guard 1. 6 316678 Screw 1 2038027 Overhead Guard 1-7 ~~ 1963916 Plug . 2 1959533 Screw. 6 8 1363917 Plug . 3 920162 Washer 1212 4 216877 Nut 66 264194 Sealant . ARAR 5 1843647 Handi 14 (©1967 HYSTER COMPANY ‘See Service Manual enia7 {or service proceduresHYSTER sco cone cue COUNTERWEIGHT (Figure 5) Bot__Part No,_Neme Of Part ty. 1 287851 Hex Head Bot . 2. 8 2014495 Counterweight . 1 2 296418 Washer . 2 6 299708 Bolt .. 3 2014494 Clamp 2 7 296431 Washer . 4 2014493 Plate 1 (©1997 HYSTER COMPANY ‘See Service Manual ene? for service proceduressen ooegieen HYSTER NON-SUSPENSION SEAT (Figure 6) rt 1364378 Seat Assy .. 1340172 Seat Rall (RH) sees Ace 1 1 18496 Hox Head Bolt ..... 48 18727 HexHead Bolt ....... 4 2 15175 Washer 4 9 221783 Washer ... 2 3 145639 Nut 4 10 395988 Base... 1 4 1351473 Seat . 1 11 835991 Cover... it 5 1954140 Seat teeters & 12 222029 Rivet. 4 6 1940171 Seat Rail (LH) . 1 ©1997 HYSTER COMPANY ‘See Service Manual enig7 for service proceduresHYSTER sean coe wean SUSPENSION SEAT (Figure 7) (©1907 HYSTER COMPANY See Service Manual for service procedures en97Page 11 ‘SERIAL CODE Gi6i-EUR HYSTER SUSPENSION SEAT ef__ParlNo, Name OtPart_____aty 1376681 Seat Assy (Fabric Cover) ~ 1 18° 1362081 Knob 1 1976677 Seat Assy (Vinyl Cover) ........ 1 14 1862062 Tape ....eseeeceeceeeeseesee 7 1 1962047 Back Cushion (Vinyl Cover).... 1 15 1882063 Hip Restraint . 1 4 1874179 Back Cushion (Fabric Cover) .. 1 16 1862084 Hip Restraint . 1 2 1862048 Seat Cushion (Vinyi Gover) ....°1 17 260045 Grommet ...... 1 2 1974180 Seat Cushion (Fabric Cover)... 1 18 18496 Hex Head Bolt ...sesseeesseeee 4 8 1962049 Shock AbSObEr sees T 19 15175 Washer .. 4 4 1954140 Switch Assy ...... + 1 20 1874750 Seat Belt (Optional) ............ 4 5 1862052 Block +1 21 879199 Hex Head Bolt (Optional) . 2 6 1862053 Shaft +1 22 379697 Washer (Optional) . 4 7 1902496 Cover ....seseereessseeerss 1 28 979698 Nut (Optional) ....... 2 8 1392495 Cover .. +1 24 1878305 Kit-Slide Rail . 1 9 1874188 Cover .... +1 25 1967137 Kit-Spring 1 10 1362058 Holder . +1 26 1978307 Cable .. a Wt 1974190 COVOF vesseeseeeseseereneesee T 12 1360872 Cover (Reat)...sseseesereeeee 1 1962085. Kit-Hardware . 1 (©1007 HYSTER COMPANY See Service Manual ene7 for service proceduresei97 a & aS g ai] fs i ag) @ § g flgé ; 3} 2 8 4 & i E ni 3 * i é for service procedures‘Ret__PartNo. Name OtPart___aty Page 13, [SERIAL CODE G160-EUR LABELS & PAINT HYSTER ‘Ret PartNo, Name OtPart ___aty 1 1999828 Label-No Riders .......00..-. 1 19 1999674 Label-Hyster . ee. 2 1836592 Label-Operator Warning +1 20 2304044 Label-Pinch Point . Hl 3 895988 Base. oe - 1 24 2310911 Label-Park Brake 4.2.6.6... 4 4 222029 Rivet. 7 seessss 4 22222020 Rivet 4 5 936991 Cover... a +1 23 1984777 Nameplate . 1 6 1826205 Label-Operating Manual +1 24 389687 Cover........ 1 7 2809284 Label-Pinch Point +2 26 2309076 Label-Sideshift . ieee 8 2303178 Label-Tit.. s+ 1 26 2808226 Label-Fork Spread .......6.46 1 9 1895143 Label-Tip-Over ....sscsces65 2 27 2907591 Plate....eeeesscesecseeseees FT 10 143276 Label-Mast Warning +1 28 1385099 Label Hydraulic Oil Fill .... 1 11 1839672 Label-Hyster .. + 2 29 2015059 Label Chart Model — 1.60 .. 1 12 1339830 Label-Mast Warning = 2 29. 2015060 Label Chart Model -1.80....... 1 13 1939892 Label-Pinch Point ............. 3 29 1839867 Label Chart Model 2.00....... 1 14 1295164 Label-Battery Disconnect ...... 1 301345808 Paint-Nugget Yellow 3.8L ..... AR 45 320037 Label-Patent Plate . 1 80 1846809 Paint-Nugget Yellow Spray .... AR 16 1885138 Nameplate ........ 1 30 816844 Paint-Red Spray .... AR 17 1342699 Label-Battery Spacer . - 1 30 1844902 Paint-Low Gloss Black 3.8L ... AR 18 2013578 SHP ....eeseeeeseeessesesse AR) 30 1944901. Paint-Low Gloss Black Spray .. AR (©1997 HYSTER COMPANY See Service Manual ene7 for service proceduresHYSTER sen cope. NOTES (©1997 HYSTER COMPANY See Service Manual enia7 for service proceduresseu croton th HYSTER DRIVE AXLE MASTER DRIVE UNIT .. seeseesees Page 16 TRACTION MOTOR PREMIUM .. ‘TRACTION MOTOR ‘STANDARD . ‘TRANSMISSION (©1997 HYSTER COMPANY See Service Manual enie7 for service proceduresHYSTER sen cone ee ev8 MASTER DRIVE UNIT (Figure 9) (©1997 HYSTER COMPANY See Service Manual enisT for service proceduressens cope cies HYSTER MASTER DRIVE UNIT Key ‘A: RH Drive Unit (Without Brush Wear Indicators) B: RH Drive Unit (With Brush Wear Indicators) : LH Drive Unit (Without Brush Wear Indicators) D: LH Drive Unit (With Brush Wear indicators) aty Qty Ret__Part No, Name Of Part ABCD Ret PartNo, Name Of Part ABCD 1 287860 Hex Head Bolt 444 5 sees Transmission ..00-1 111 2 292682 Lockwasher .. 444 7 Figure 10 3 320189 Washer .... 444 6 902977 Wheel Nut. 5555 4 sees Traction Motor 1 7 39349 O-Ring ... 1141 Figure 11 8 293688 HexHeadBolt .......5 5 5 5 4 s+++ Traction Motor 1.1 9 296426 Washer 35555 Figure 12 (© 1957 HYSTER COMPANY See Service Manual eii97 {or service proceduresHYSTER sen.cooe e208 TRANSMISSION (Figure 10) (©1997 HYSTER CONPANY Soe Service Manual en97 for service proceduresae HYSTER TRANSMISSION Key ‘A: RH Transmission B: LH Transmission ty ty Ref__Part No, _Name Of Part AB Ret PartNo, Name Ot Part AB 1382579 ‘Transmission (RH) 1. 87 1982523 Shim0.279mM «......... ARAR 1382578 Transmission (LH) . sew 1 38 1982524 Shim 0.508 mm. se. ARAR 1 4881111 Housing - 90 39369 O-Ring ........ ot 1 1981105 Housing ieee 1 40 1382595 Oil Seal wa 2 1985005 Bracket ..seseeeeeeeeeee tw 41 1981122 Cap a1 2 1985093 Bracket seeseen 1 42 1982694 Sleeve « at 3 1385096 Bracket 1 43 1981104 Brake Disk a4 3 1385094 Bracket 1 44 182907 Washer . .td 4 1881112 Cover = 45 293681 Hex Head Bolt . add 4 1981106 Cover ....ceeeeee 1 46 © 1382607 Shim 0.432 MM ....4..44. ARAR 5 1882592 Shield... 47 1382508 Shim 0.457 mm . 5 1382591 Shield... 48 1382509 Shim 0.508 mm 6 292514 Hex Head Bolt . wd 49 1382510 Shim 0.559 mm 7 ~~ 292682 Washer .. 1 50 © 1982611 Shim 0.610 mm 8 320159 Washer 1 51 1382512 Shim 0.635 mm .......... ARAR 9 302885 Dowel 2 52 1382508 Bearing . 10 178901 Seal ..... ARAN 53 185658 Bearing Cone : 11 1381103 Shaft 12 34820 Oil'Seal ....... 13 167971. Bearing ...... 14 167970 Bearing Cone . 15 $1676 Boating .....esseeseseereee 16 961675 Bearing Cone . 17 1381100 Gear....... 18 2021914 Washer 19 904406 Nut ss... 20 1382502 Cap . 21 299614 Hex Head Bolt 22 39866 O-Ring ....... 23° 1382517 Shim 0.127 mm 24 1382518 Shim0.178 mm .... 25 1082519 Shim 0.279 mm . 26 1982520 Shim 0.508 mm . 27 — 1875440 Bearing .... 28 1374899 Bearing Cone . 28 1981101. Shaft .. 1 1 1 1 2 R 1 54 4382504 Oil Seal ... 1 85 1981124 Spacer .. 1 56 2802735 Park Brake 1 1 1 1 1 1 1 7 57 1982513 Shim 0.127 mm 58 1982514 Shim0.178 mm 59 1982615 Shim 0.279 mm 60 1982516 Shim 0.508 mm 61 156205 Oil Seal . 1381123 Spacer 1981119 Washer . : 1981120 NUL sseseeesesererees 260084 Brake Assy 293628 Hex Head Bolt .. 293633 Hex Head Bolt . - ARAR 682310841 Stud .. 69 292682 Washer . 70 264184 Adhesive 71 284159 Adhesive 72 14367 Plug... 30 1881107 Gear Set . 73 15290 Plug... +e. 31 261979 Washer ..... 7A 24420 Breather ....eeeveereseeee TD 32 14722, Hex Head Bolt 75 3020389 Grease ARAR 93 159895 Bearing ........++ : 76 16041 Grease Fitting. ...esseeeree 11 34 183804 Bearing Cone ......c.0s66.1 1 77 251099 Adhesive sees ARAR 35 1382521 Shim0.127mm .......... ARAR 78 «293631 Hex Head Bol 155 96 1382522 Shim 0.178 mm . | ARAR 79 = 902977 Nut. 155 (©1997 HYSTER COMPANY See Service Manual ens7 for service proceduresHYSTER sens cove -sun TRACTION MOTOR STANDARD (Figure 11) 2 / ©1907 HYSTER COMPANY ‘See Service Manual ens7 for service procedures.Pago 21 HYSTER SERIAL CODE G160-EUR, TRACTION MOTOR STANDARD Ref___PartNo, Name Of Part Gly Bet__PartNo,_NameOtPat ty 2309091 Traction Motor . vs 1 19 2802280 Insulator . me (Without Brush Wear indicators) 20 2804670 Field Coll Set ......seeveeee 7 Group no, 8620088 21 2084176 Pole Piece. a4 1 2309525 Nut .. +2 22 2084120 Armature . 1 2 2811684 Lockwasher ... 2 22 2084121 Armature Shaft 1 3 2909525 Nut .. 2 22 82415 Woodtuf Key ...eeseeeeevee 7 4 16905 Lookwasher +2 22 2810529 Washer . 1 5 2811684 Lockwasher 2 23 2810338 Cover (End) 1 6 — 2802673 insulator . -2 24 2306090 Screw. 4 T 2306080 Screw a 4 25 17181 Screw. 8 8 2808141 Commutator End Assembly... 1 26 2809528 Screw. 4 9 2811415 Bearing .. +1 27 2908954 Spring 4 40 2304615 Snap Ring 1 28 2311308 Screw. 8 41 2807969 Brush Holder +4 29 8 2307052 BHUSh ..seeseeesesceseeeees 4 12 2309525 Nut .. +2 29 2308510 Brush Kit 1 13 2811684 Lockwasher ss 2 90 1885089 Retaining Ring - 1 14 2309525 Nut .. 2 81 2810512 Terminal Assy we 15 15905 Lockwasher +2 82 2802280 INGULaLOL ees eeeseseeeseeeees 2 16 2307351 Washer -2 93 2911793 Enclosed Cover Kit"EE"....... 1 17 2802673 InBUlatOr eee eeeeseeeeeene 2 18 2034648 Field Coll Housing . = 1 ® Included in kit 2608510 ©1097 HYSTER COMPANY See Service Manual enis7 for service proceduresHYSTER sen cove een TRACTION MOTOR PREMIUM (Figure 12) 23 24 33 Fuios4 (©1997 HYSTER COMPANY See Service Manual enis7 for service proceduresPage 23, ‘SERIAL CODE G160-EUR TRACTION MOTOR PREMIUM Ref PartNo, Name OfPart _aty HYSTER 2809578 Traction Motor ................ 1 22 2084120. Armature .........- 1 (With Brush Wear Indicators) 22 © 2034121 Armature Shaft..... 1 Group no. 8620089 22 32418 — Woodruff Key ....esseseseeee 1 1 2309525 Nut... 2 22 2810529 Washer . 1 2 2811684 Lockwasher 2 23 2810338 Gover (End) . 1 3 2909525 Nut... 2 24 — 2306090 4 4 15905 Lockwasher 2 17151 8 5 2811684 Lockwasher 2 26 2309528 4 6 2302673 Insulator . 2 27 308054 4 7 — 2306090 Screw. . 4 28 eatig08 8 8 — 2308377 Commutator End Assembly... 1 29 @ 2305203 4 9 2311415 Bearing . : 1 292908516 1 10 2304615 Snap Ring .... seo 1 80 1885089 Retaining Ring . 1 11 2307869 Brush Holder . 1 81 2810512 Terminal Assy 2 12 2309525 Nut ....... 2 32 2302290 Insulator ...... 2 18 2811684 Lockwasher .........+.:0+... 2 38 2311783 Enclosed Cover Kit “EE” . 1 14 2909525 Nut .. 2 15 15905 Lockwasher 2 2310597 Thermal Sensor Assembly ..... 4 16 2907351 Washer 2 1985087 Thermal Sensor 1 17 2302673 insulator .. 2 1985086 Terminal . 1 18 2034178 Field Coil Housing . 1 2808978 Connector ....sseseecsseseees 2 19 2902290 Insulator .. 2 2310058 Jumper . 2 20 2304670 Field Coll Set ..... 1 21 2034176 Pole Piece.. 4 Included in Kit 2808516 (©1967 HYSTER COMPANY See Service Manual enie7 {or service proceduresHYSTER sens cone cro.ctn NOTES (©1997 HYSTER COMPANY See Service Manual enis7 for service proceduresset cont orem HYSTER STEERING HAND PUMP ... Page 28 ‘STEERING MOTOR (STANDARD) ..........-0.000000+ -- Page 33. STEERING MOTOR (PREMIUM) .......0ssssessseeseeereeres Page 34 STEERING POD ......eseseeseeees Page 26 STEERING PUMP ...... - Page 32 TRAILAXLE oo eeseceeeesseee + Page 30 (©1997 HYSTER COMPANY ‘See Service Manual eni97 for service proceduresHYSTER Pari STEERING POD (Figure 13) FL 1148 (©1997 HYSTER COMPANY See Service Manual eni97 {or service proceduresPage 27 SERIAL CODE G160-EUR STEERING POD HYSTER Het PartNo, Name Of Part___@iy 1 © 1949597 Plug 1 20. 1949607 Pin. 1 1 1343596 Bracket 4 2 18212. Spit Pin 1 2 1876744 Cover (Upper) 4 22 1389084 Spring ..... + 3 1976745 Cover (Lower) . 4 23 1996821 Gears... 1 4 1937196 Screw 6 24 1390205 Optical Encoder . 1 8 1843574 Knob 4 25 1339080 Housing .. 1 6 296472 Screw .. : 2 26 2033605 Steering Colurnn 1 7 820155 Washer . ae 1 = See Soa . : 8 eae poy certs 1 29 “e308 Hex Head Bolt 4 10 296010. Hex Head Bolt acre ees ee oor eerie ie He leioiae Na } 3t 48184 Washer... 4 32 298762 HexHead Bolt 4 fe eee : -2 33 298779 Lockwasher 4 18 136749 HexHoad Bolt .........cs 4 3g 4949679 Bracket : 44 292681 Lookwasher .. 4 35° 4g76748 Pug. a 18 1878600 Spring - 1936 sess Hand Pump... a 16 1395987 Shatt 1 Figure 1a 47 1450503. Hor Button... 4 48 1929250 Steering Whee! 1 Monotrol Pedal 19 1864271 Latch .eseeeesseesee 1 © Forward/Reverse Lever 1907 HYSTER COMPANY See Service Manual enio7 for service proceduresHYSTER sen cone oes. cun HAND PUMP (Figure 14) (©1997 HYSTER COMPANY See Service Manual enis7 for service proceduressen cope 2 HYSTER HAND PUMP ‘Het__PartNo. Name OtPart __________Qty Ret __PartNo. Name OtPart __aty 2033603 Hand Pump . 131451703 Plates... scevsvevevsvesevesee 1 1 1451695 Seal Ring . 14 1451704 Gear Set ...... 1 2 se. Housing 15 1451705 Relief Valve Assembly 1 3 1956335 Ball... 16 1451706 End Cover .. 1 4 1481696 stop . : 17 ® 1451708 O-Ring .... 8 5 1451697 Bearing ....... 18 1481710 Screw. : 4 6 ++. Spool : 19 1451712 SCIOW. eae eeseeeseee 1 7 1451698 Pin... 20 1451713 Sorew....... 4 8 ses Sloeve ... 21 1481711 Screw... 1 9 1451699. Spring Set 22 8 1451708 O-Ring ..... 2 10 1451700 Shaft 23 AABYTO7 Ball. eeeeeesseeceseseeeees T 11 1451701. Spacer . 12.8 1451702 O-Ring so... @ Included in Seal Kit 1451714 (©1907 HYSTER COMPANY ‘See Service Manual shis7 for service proceduresHYSTER enn cooeote sin TRAIL AXLE (Figure 15) (©1997 HYSTER COMPANY Seo Service Manual eis7 for service proceduresRet__PartNo,_NameOtPert_____ Gy Page 31 SERIAL CODE 6160-EUR TRAIL AXLE HYSTER 1 2034281 Potentiometer 117 1453615 Actuator...... 1 2 2004005 Ty-Wrap 2 17 2018461 Bush 1 3 292503 Hex Head Bolt ... 117 1454553 Seal Kit . 1 4 1991075 Bracket 1 18 2013468 Trail Axle. 1 5 302191 Setsorew ...... 148 sess Tyre & Wheel. 2 6 196687 Nut oes 2 Figure 92 7 — 1891078 Bracket . 1 20 158609 Hub Cap . .2 8 292681 Lockwasher .... 2 21 2310084 Spacer 2 9 196681 Hex Head Bolt . 2 22 2307438 Seal . 4 10 18247 SplitPin ss... 3 23 80208 Beating Cup ...... 4 Th 2805981 NU veeeeceeeereeeteesesees 8 26 1845091 Circlip...... 4 12 320181 Washer .......... 3 25 302977 Nut . 0 18 1391077 Special Fitting .. +1 26 2019648 Hub . 2 14 221771 Washer . : 12 27 agt0B41 Stud ...... 5 18 200441 HexHead Bolt ... 12 28 80198 Beating Cone . 14 16 16556 Fitting... seeseeseseseeseee 2 16 16481 O-Ring 1 264184 adhesive ......... AR ‘©1008 HYSTER COMPANY See Service Manual 2resi98 for service proceduresHYSTER sen. coe cre cn STEERING PUMP (Figure 16) 12 Ret__Part No, Name Of Part ty 2033614 Steering Pump 1 1922360 Screw 2 2084266 Kit-Joint . 3 354669 Needle Bearing . 4 358072 Circlip.. 5 6 7 2300077 Idler Shaft. 8 954671 Pin... @ 388076 Plug . 2906507 Oil Seal 11 958073 Key. 12 2309808 Drive Shai 358069 Gear . 380770 Spacer sonrsses Ss ‘©1897 HYSTER COMPANY ‘See Service Manual 6/97 for service proceduresPage 33 SERIAL CODE G160-EUR STEERING MOTOR STANDARD (Figure 17) ‘Steering Motor «2... BOlt..sssesesseseeseeee Nut Cover 1376961 14 1909978 15 1391773 16 1208875 HYSTER 1 1 2 2 2 3 1 4 1991762 Spring 1 17 1934993 5 1452880 Bearing 1 18 15155 6 1452881 Cover... 1 49 1908893 7 — 1452882 Gasket . + 201452893 8 1450475 Screw 2 21 1876981 9 1991769 Brush Holder . 1 22 1452888 40 1452891 Kit-Terminal 2 28 1452869 41 1991771 i 4 24 s0tt81 12 139172 4 ©1997 HYSTER COMPANY See Service Manual enis7 for service proceduresHYSTER seni cove otecin STEERING MOTOR PREMIUM (Figure 18) 2434900 Stooring Motor ....ssssseses» 1 14 1976961 Screw : Vo 1452678 Bolt... eeececceeesesesees 2 18 1909978 Spring . 2 1301760 Nut. 2 48 1991773 Bushing .. 3 1452879 Cover ..... se 147 1808875 Insulator . 4 1391762 Spring Washer . 1 48 1334098 Washer Recep Cee eect leceeat@ 18185 Lockwasher 7 1482862 Gasket Pet eee eee 8 1450475 Screw. 2 res nae 22 1452887 Armature e 9 1391769 Brush Holder 1 ‘ 10 1452891. Kit-Terminal . a 23 tabeees Boag 11 1452884 Wire Assembly . 1 24 1452889 Cover........ 12 1891771 SOLOW. serene 4 25 801181 Oil Seat 191452885 BHUSN.eeeeeeeeceseeeseeses 4 26 1452890 Connector ......+.++ (©1007 HYSTER COMPANY See Service Manual ent/97 for service procedurescena cope otw-cu8 HYSTER BRAKE ACCELERATOR PEDAL .......... BRAKE ASSY .... BRAKE MASTER CYLINDER .......... BRAKE PEDAL LINKAGE . PARK BRAKE LINKAGE .. PARK BRAKE... (©1997 HYSTER COMPANY ‘See Service Manual enis7 {or service proceduresHYSTER sens coor ore £08 ACCELERATOR PEDAL (Figure 19) (©1997 HYSTER COMPANY ‘See Service Manual eiti97 for service proceduresPage 87 ‘SERIAL CODE G169-EUR ACCELERATOR PEDAL Forward/Reverse Pedal ‘Monotrol Peda! ty Ret PartNo, Name OtPart__________A 8 Ref __PartNo, Name OtPart_. ___ AB HYSTER aty 2013359 Pedal (Monotrol) . 1 19 2033120 Spring . 4 2032999 Pedal ... : 1 20 925588 Clamp . 2 1840470 Pads... seeeseeeses 1 21 2082996 Shaft ...... 3 2012437 Switch Hamess . 1 22 292501 Hex Head Bolt 4 220428 Screw. 4 23 136687 Nut. : 5 53162 Lockwasher . 4 24 15127 Washer ........+- 6 16865 Nut... 4 25 20411 Link 7 963128 SWitth ee eeseeeeeseeee 2 26 2908011 8 2013436 Wire Hamess .. 1 27 306862 9 925699 Spring ........ 2 28 302141 10 220493 Screw... 6 29 2033815 11 320156 Washer 4 30 352885 12 362036 Washer 2 31 296215 18 1806621 Washer 2 82 292501 Hex Head Bolt 14 114912 Ty-Wrap . 2 33 325182 Nut... 15 296215 Screw 2 84 292680 Lockwasher 16 2038119 AIM ve eesseesseseee 1 17 2033815 Arm .... ~ 251099 Sealant 18 19979 Pin 1 360387 Loctite . (©1997 HYSTER COMPANY See Service Manual enis7 for service proceduresHYSTER sepa cove oun cuh BRAKE PEDAL LINKAGE (Figure 20) (©1907 HYSTER COMPANY See Service Manual eni97 for service proceduresseve cone coon HYSTER BRAKE PEDAL LINKAGE 10 211878 Master Cylinder ....... 10 2806125 Push Rod 10 2804690 Seal Kit 11 299615 Hex Head Bolt . 12 320187 Washer . 13 302400 Nut 339068. Lubricant . 251099 Adhesive . @ Monotrof Pedal > Forward/Reverse Lever 1 2034096 1 14 114312 Strap, Clamp 1 2 2305586 1 15 2806538 Spring eee 3 920157 4 16 1944820 Retaining Ring .....eeeeee 1 4 193683 1 17 296226 Capscrew : 2 5 2811664 4 18 8 2089287 Plate 1 6 15212 : 2 18 2033914 Plate 1 NE 1 19 2308828 Bush... 2 8 14269 Fitting ae ipsttHieud tteebesesedheam cs 1 9 BIOGTBB HOSE vesesesseesvesesseseees 2 | Bi 2089818 Bracket 1 4 2 ~~ 183484 Grommet . 1 1 1 2 2 2 (©1007 HYSTER COMPANY ‘See Service Manual eni97 for service proceduresHYSTER sence oreo-cun BRAKE MASTER CYLINDER (Figure 21) 1 2811873 Master Cylinder . 1-7 292501 Hex Head Bolt ..-........+ 4 2806125 Push Rod ....... .1 8 16687 Nut .. 1 2804690 Seal Kit ..sseseeeecrerereere 1 9 193484 Grommet... 2 28097989 ClaMP vieeseeeeseesrerereeres 2 10 9060656 Brake Fluid (1,0 L) 3 2909267 a 11 10 281969 Brake Fluid (6,0 L) 4 2309541 4 10 $060857 Brake Fluid (05L).......- 5 2305187 Clamp +1 1 313805 Nut .. : 6 292500 Hex Head Bolt 1 (©1907 HYSTER COMPANY ‘See Service Manual enisT for service procedureseet HYSTER NOTES =) (©1997 HYSTER COMPANY See Service Manual 6nie7 for service procedures:HYSTER sea. cove ai-cin PARK BRAKE LINKAGE (Figure 22) 10 9 a z 6 5 4 123 ri 2 (©1907 HYSTER COMPANY See Service Manual enis7 for service proceduresPage 43 HYSTER SERIAL CODE G160-CUR, PARK BRAKE LINKAGE ‘ef__Part No, Name Of Part Qty Bet__PartNo, Name Of Part Qty 1 2904966 Cam .. 1 23820159 Washer 2 16865 Nut... 2 24 18155 Washer 2 18419 Lockwasher 2 25 8 2905287 Link . 3 2909240 Switch ..... 1 ® 2809815 Bush 4 2902902 Insulation........ 1 26 292518 HexHead Bolt 5 290880 Nut .. 2 27 ® 290208 Pin . 5 197065 Washer . Tl 2 28 > 2802565 Ball Joint 5 15151 Lockwasher . ieee 15025 Nut . 6 239503 Nut ....... 2 80 2811835 Rod . 7 292681 Washer . a tinet 138 Pin 8. 2906881 Plate + 82 199 Pin 9 2311088 Plate... eee See eee 10 320157 Washer ........ 2 34 221454 Hex Head Bolt ... " 990451 Brake Assy 4 95 P 15175 Washer .... 11 929617 Pedal Pad 1. 96 P 2906788 Shim. Sei. Soe a 12 136704 Hex Head Bolt Cerrar 13 2808749 Bracket Aes age qeeisten 14 2305554 Handle 1 41 320156 Washer 15 2810764 Cable ..... HHH 45200 Pin pee a ene 1 43 292682 Lockwasher 17 2808742 Spring 1 18 18134 Washer . 2 251099 Sealant 19 18026 Nut .... 2 339068 Lubricant . 20 2305981 Ball Joint .. 1 21 15186 Washer .eeceeeeeesceseisee 1 @ Included In Repair Kit 2902512 22 ® 2310295 Bellorank .. 1 P Included In Repair Kit 2311979 (© 1007 HYSTER COMPANY See Service Manual for service procedures eit/97HYSTER senwucone cic PARK BRAKE (Figure 23) 14 8 Ref__PartNo,__Name Of Part Qty Ret___PertNo.__Name Ot Part aty 2302735 Park Brake ~ 1-7 809854 Spring ...... 1 1 2013879 Carrier Assy ceeeeaal 15241 SpiitPin..... 1 1 2019881 Carrier .. -1 9 303669 Nut... 1 2 2019880 Pad -1 10 303668 Washer . 1 3 2019876 Cam -1 1 2019878 Plato 1 3 2018877 Cam. 1 12 303672 Screw 2 4 281971 Pad..... -1 13 319667 Bush. 4 5 303652 Back-Up Plate . - 1 14 309674 Nut 2 6 803653 Pin +2 15 803660 Spacer . 2 ©1997 HYSTER COMPANY ‘See Service Manual ene7 for service procedures.ae HYSTER BRAKE ASSY (Figure 24) n 13 6 ‘Ret__PartNo.__Name Of Part Qty Ast PartNo, _Name of Part oy 260084 Brake Assy .. 1 7 319667 Bush...... 4 301992 Piston.........604 1 8 292777 Clip. 2 1 801995 Insert .........ss 1 9 1924049. Kit, Pad 1 2 292778 Piston... 1 9 1323956 Pad. 22 3 292780 Dust Cover 1 10 301996 Cartier 1 4 292779 Seal ....-..4- 1 11 1928955 Screw. 2 5 301994 Bleeder Screw . 2 12 808673 Washer ......eeeveseseeeee 2 6 301997 Retainer... seers 2 18 808674 Locknut 2 (©1997 HYSTER COMPANY See Service Manual ener for service proceduresHYSTER senate ou. NOTES (©1097 HYSTER COMPANY See Service Manual enis7 for service proceduressew oregon HYSTER ELECTRICAL BATTERY CONNECTOR erry Page 67 CONTACTOR PANEL .. Page 56 CONTACTOR PANEL POWER STEERING AND LINE .. Page 54 CONTACTOR PANEL TWO-SPEED PUMP .......ecscescseeeseees Page 60 COWL ELECTRICAL, FRONT v.eseesecerecsenes Page 63 ‘COWL ELECTRICAL, REAR . Page 64 ELECTRICAL SYSTEM ‘CONTACTOR HYDRAULICS ae - Page 48 ELECTRICAL SYSTEM SINGLE-SPEED PUMP " = Page 52 ELECTRICAL SYSTEM TWO-SPEED PUMP ........- - Page 50 INSTRUMENT PANEL ... - Page 65 LINE CONTACTOR .......... Page 61 PUMP CONTACTOR ‘SINGLE-SPEED PUMP .. : Page 57 PUMP CONTACTOR TWO-SPEED PUMP ..... seen Page 58 SHIFT LEVER .. Mareratoiaraa tae Page 66 ‘STEERING CONTACTOR ... Page 62 (©1907 HYSTER COMPANY See Service Manual enia7 for service proceduresHYSTER sem oopeareecin ELECTRICAL SYSTEM CONTACTOR HYDRAULICS (Figure 25) (©1997 HYSTER COMPANY See Service Manual for service procedures eni97Page 49 SERIAL CODE G160-EUR ELECTRICAL SYSTEM CONTACTOR HYDRAULICS HYSTER 1 16056 Hex Head Bolt . cee 2 15 292681 Lockwasher 2 2 16227 Screw... 16 1304845 Power Cable .. 1 2 264134 Sealant ....., 16 196681 Hex Head Bolt ......seeeeeeee 2 3 18086 Nut 16 20157 Washer ..e.seeseescesercsese 2 4 845802 Insulator 16 292681 Lockwasher 2 5 2310851 Cover : 17 1454527 Power Cable .. 1 6 1687 Hex Head Bolt . 17 1454540 Power Cable .. 1 6 296314 Sealant . 18 1454528 Power Cable 1 6 289536 Sealant ...... 18 1454541 Power Cable .....seessecevecee t 7 ® 1394868. Wire Harness (Main) 18, 14b4e20 Power Cabs 1 7 ® 1994826 Wire Harness (Main) (19 aeaee oer canes : : 7 © 1394870 Wire Hamess (Main) 20 1454530 Power Cable (Positive) ......... 4 7 © 1394861 Wire Hamess (Main) .. 20 1454543 Power Cable (Positive) ......... 1 7 1894869 Wire Harness (Main) Sate omen i 7 1894827 Wire Hamess (Main) pelastisbopcqianeritdiuaal iad i @ 1994888 SX Controller 22 1454502. Power Cable. 1 8 1198757 Silicone Grease Se Higilaeaeo, Cunen alee 1 gclegaestiLpequcsher ce 23 1454533 Power Cable . 1 a Jessosol nan Heed Bont 23 1454546 Power Cable eet apt epaniaes (canoer eanel ce i 24 1454534 Power Cable (Negative) «1.1... 1 aj) ioeoo Hex eat oot ‘> 24 1454547 Power Cable (Negative) 1 Giiitiomeat taawenee tits 2 25 1454595. Wire Assembly 1 SerereeetitE 25 1454548 Wire Assembly 1 10 1394829 Circuit Sensor .....essseeececee 1 Noli -ensopetience if “3 26 1454536 Wire Assembly 1 26 1454549. Wire Assembly 1 10 320184 Lockwasher 4 27 1454507 Wire Assembly 1 10 296042 Lockwasher ...... ae : 27 1454850. Wire Assembly . 1 41 1994891 ContactorPanel..sceseeeee 1 5g 445458 Wi ire Assembly ad 11 296010 Hex Head Bolt . 24 28 1454551 Wire Assembly ad 11 292681 Lockwasher .. 4 29 1454589 Wire Assembly ...... 1 12 1452793 Wire Assembly . a 29 1454562. Wire Assembly .. 1 13 1994842 Power Cable . cesses 199 2018774 Clamp 7 ieee poeta ieeeate +2 31 196749 Hex Head Bolt - 2 fe eeeen lee Wiaeirae ~2 32 320188 Washer .. Tine a fs eee Locawasher = 233 292681 Lockwasher ....seeeeeveesceee 2 14 1394843. Power Cable . 1 34 289508 Nut... 2 gee ee Heed Et 2 5 1961415 SEM Diagnostic Handset Kit .... 4 14 820158 Washer 2 35 1961414 Cable Assembly eee 14 292681 Lockwasher ... 2 35 1961412 Cable Kit .. i 44 299503 NUt ese ese see 1 15 1394844 Power Cable . 1 2 with BDI 18 136881 Hex Head Bolt . +2 with BDI 15 320156 Washer . 2 (©1007 HYSTER COMPANY Soe Service Manual enis7 for service proceduresHYSTER sen core cree ELECTRICAL SYSTEM TWO-SPEED PUMP (Figure 26) (©1997 HYSTER COMPANY See Service Manual enig7 for service procedures15 15 15 16 (©1997 HYSTER COMPANY 15056 16227 264134, 15086 ‘345802 2310551 16387 296314 299536 1994868, 1304826 1394870 1394861 1394869 1394827 1994838 1198767 292681 298090 1394833, 296090 292681 1994829 302026 320184 298042 1394832 296010 292681 1452793 1394842 136681 320158 292681 1394843 136681 320156 292681 299503 1304844 136681 320186 292681 1304845 Page 51 SERIAL CODE @160-EUR, ELECTRICAL SYSTEM TWO-SPEED PUMP Hex Head Bolt .....:. ‘Screw Sealant . Nut Insulator... Cover . Hex Head Bolt Sealant .. Sealant . Wire Harness (Main) .... Wire Harness (Main) Wire Harness (Main) Wire Hames (Main) .... Wire Harness (Main) Wire Hatness (Main) ... SX Controller ........ Silleone Grease ...... Lockwasher . Hex Head Bolt Contactor Panel Hex Head Bolt ..... Lockwasher . Circuit Sensor . Screw... Lockwasher , Lockwasher Contactor Panel .. Hex Head Bolt . Lockwasher ........ Wire Assembly ...... Power Cable... Hex Head Bolt Washer .... Lockwasher .. Power Cable... Hex Head Bott . Washor ..... Lockwasher ..... Nut . Power Cable Hex Head Bolt .. Washer Lockwasher .. Power Cable 16 16 16 7 7 18 18 19 19 20 20 24 at 22 22 23 23 24 24 25 25 26 26 a7 a7 28 28 29 29 35 35 36 37 38 39 a b 196681 320157 292681 1484527 1454540 1454528 1454541, 1454529 1454542 1454530 1454543, 1454531 1454544 1454532, 1454545, 1454533, 1454546 1454534 1454547 1454535 1454548, 1454536 1454549 1454537 1454550 1454538 1454551 1454539 1454552, 2014774 136749 920158 292681 239503 1961415 1361414 1361412 1394847 1304865 325809 2305197 with BDI with BDI See Service Manual for service procedures HYSTER Hex Head Bolt Washer .. Lockwasher Power Cable Power Cable Power Cable . Power Cable........... Power Cable ........60.. Power Cable .... Power Cable (Positive) ... Power Cable (Positive) . Power Cable Power Cable Power Cable Power Cable Power Cable .. Power Cable... Power Cable (Negative) ........ Power Cable (Negative) ........ Wire Assembly . Wire Assembly Wire Assembly Wire Assembly . Wire Assembly .. Wire Assembly ...... Wire Assembly Wire Assembly ..... Wire Assembly .... Wire Assembly .. Clamp Hex Head Bolt ........ Washer .. : Lockwasher Nut .. ‘SEM Diagnostic Handset Cable Assembly . Cable Kit ...... Bussbar ....... Wire Assembly Fuse Wire Assembly eii97HYSTER sen cose aes ELECTRICAL SYSTEM SINGLE-SPEED PUMP (Figure 27) (©1997 HYSTER COMPANY ‘See Service Manual tor service procedures eio71 15056 2 16227 2 264134 3 15088 4 325819 5 2810551 6 16387 6 264134 6 239536 7 * 13904868 7 * 1304826 7 © 1394870 7 © 1304861 7 1394869 7 ~~ 1394827 8 1304838 8 1198757 8 1334820 8 292881 @ 1361418 8 296090 9 1394833, 9 296090 9 292681 10 1994899 10 1198757 10 296010 10 292681 11 4394846 12 1452703, 13 1304842 13° 196681 13 820156 13 292681 14 1994843, 14 198681 14 920156 14 292681 14 239503 15 1904844 15 196681 15 320186 (©1907 HYSTER COMPANY Page 63, ‘SERIAL CODE @160-EUR ELECTRICAL SYSTEM SINGLE-SPEED PUMP Hex Head Bolt ... Screw... Sealant .... Nut Insulator Cover... Hex Head Bolt . Sealant . Sealant > > Brvwn dun Wire Hamess (Main) . Wire Harness (Main) . : Wire Harness (Main) ....... Wire Hamess (Main) . Wire Harness (Main) . SX Controller Silicone Grease . Hex Head Bott Lockwasher Spacer .... Hex Head Bolt Contactor Pane! . Hex Head Bolt Lockwasher . SX Controller Silicone Grease . Hex Head Bolt Lockwasher . Bussbar . Wire Assembly Power Cable Hox Head Bolt Washer . Lockwasher Power Cable . Hex Head Bolt .... Washer .... Lockwasher ee Power Cable . Hex Head Bolt ........... Washer .esscceeceveree 15 16 16 16 16 7 7 18 18 19 19 20 20 at 24 22 22 23 23 24 24 25 25 28 28 27 27 28 28 29 29 30 31 32 33 34 35 35 35 a > Reape Radestns fee fae cea cee (sate ae ert traci e i astaatayecacee 292681 1994845 196681 320157 292681 1454527 1454540 1454528 1454541 1454529, 1454542 1454530 1454543, 1454531 1454544 1454532 1454545 1454593 1454546 1454534 1454547 1484535 1454548, 1454536 1484549 1454537 1454550 1454598, 1454551 1454539 1454552 2014774 136749 320188 292681 239503 1961415 1361414 1361412 HYSTER Lockwasher «..scssssesseeeee Power Cable .. Hex Head Bolt ... Washer .. Lockwasher ee Power Cable ...........+ Power Cable .. Power Cable Power Cable Power Cable . Power Cable... ....4 Power Cable (Positive) . Power Cable (Positive) . Power Cable... Power Cable . Power Cable Power Cable Power Cable Power Cable : : Power Cable (Negative) ....... Power Cable (Negative) Wire Assembly ..... Wire Assembly Wire Assembly .. Wire Assembly . Wire Assembly Wire Assembly Wire Assembly .. Wire Assembly Wire Assembly Wire Assembly ....... Clamp . Hex Hea Washer Lockwasher Nut ‘SEM Diagnostic Handset Kit . Cable Assembly .... Cable Kit... with BDI and BWI with BDI See Service Manual for service procedures eni97Page 54 ‘SERIAL CODE G160-EUR HYSTER CONTACTOR PANEL POWER STEERING AND LINE (Figure 28) eni97 See Service Manual tor service procedures (©1097 HYSTER COMPANYae HYSTER CONTACTOR PANEL POWER STEERING AND LINE ‘Ret__PartNo, Name Of Part Qty Ast_PartNo, Name Of Part_ Ee 1994833 Contactor Panel... 1 42 292681 Lockwasher . ar 1 1459530 Base....... : 1 18 320157 Washer . fain 2 | 1930098 Contactor (Steering Pump) .... 1 14 1483533 Bussbar......... 1 3 ' 292678 Lockwasher ........+. 2 18 — 1990938 Contactor 1 4 902018 Screw... 2 16 299508 Screw. 2 6 1974296 Bracket .. 1 17 325809 Fuse...... 1 6 989193 Fuse Block . 1 18 1301610 Bussbar........... wd 7 1964262 Fuse....... 2 19 1453532 Fuse........ 3 8 292678 Lockwasher -2 20 ° 2902637 Insulator .. 2 9 296010 Hex Head Bolt .. 2 21 1901512. Block (Con Fuse) 1 10 1364262 Fuse....... 1 22 1998356 Block (Con Fuse) 1 1 136681 Hex Head Bolt .. 2 eran eee eee eee eee eee (©1997 HYSTER COMPANY ‘See Service Manual eis7 for service proceduresHYSTER sun cone cron um CONTACTOR PANEL (Figure 29) Re Ref__PartNo, NameOfPart__aty 1394831 Contactor Panel. +1 2 889184 Contactor (Purp) ......-+.-++ 1 1 1983884 Base... ©1967 HYSTER COMPANY ‘See Service Manual eni97 {or senice procedures1300202 1300276 88238 Coil. Frame... e Contact (Stationary) . Contact (Stationary) Clamp Spring Armature . Base Carrier 1306706 988295 271892 988230 sge234 Soovounena (©1997 HYSTER COMPANY Page 57 SERIAL CODE @160-EUR PUMP CONTACTOR SINGLE-SPEED PUMP (Figure 30) 2307930 See Service Manual for service procedures HYSTER Bushing Contact Seat ‘Spring Cup Washer Nut... Kit-Contactor .... 697HYSTER senucove cen cun PUMP CONTACTOR TWO-SPEED PUMP (Figure 31) (©1997 HYSTER COMPANY See Service Manual {for service procedures enio7Page 59 ‘SERIAL CODE @160-EUR PUMP CONTACTOR ‘TWO-SPEED PUMP et__PartNo, Name OtPart ty HYSTER 2808760 Pump Contactor .. 1 43 3880331 Cartier .... 1 1 988249 Spacer . 1 44 197087 Washer ..... 1 2 18515 Washer 1 18 sees NUL eseeseeee 1 3 18155 Lockwasher .. 116 274088 ScIEW esses 4 4 293620 Hex Head Bolt +117 187066 Washer ..... 4 5 1308708 Contact (Stationary) 2 18 388244 Cover. i 1 6 1908705 Contact (Stationary) 119 388243 Clamp ose 2 7 2019601 Contact (Stationary) +2 20 988284 Cartier .... 1 8 988281 Bush. 7 1 21 388241 Ammature .. 1 9 388283. Carrier . +1 22 388242 Spring 1 10 2013602 Moving Contact . see 2 28 986298 Frame .... 1 41 388292 Seat ee eeecececesesseersesees 2 24 1800276 COW eseeveceecsererereeee t 42 +271887 Spring ....... ioe} 70 Oueee pase tsiestar rics al (©1997 HYSTER COMPANY See Service Manual ere7 for service proceduresHYSTER sen coo ore-eu8 CONTACTOR PANEL TWO-SPEED PUMP (Figure 32) Ret__PartNo, NameOfPart ___—__—aty 1 ® 1994832 Contactor Panel .... 2 8 2308760 Pump Contactor ... re) <» 2 86/48 Volt with On-Demand Steering ©1007 HYSTER COMPANY ‘See Service Manual enie7 for service procedures