FORTIS®

S120FT
(G004)
S/N G004V05311J
This truck may contain certain non-production and/or special content. Every effort has been made
to reflect that in this manual, but the user is well advised to refer to the special content information
that pertains to this specific serial number truck. If so equipped, the special content information
will be located in the last chapter of this manual.

G004V05311J ©2011 HYSTER COMPANY

05/2009
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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

10 MAST-TWO STAGE LIMITED FREE-LIFT

11 MAST-TWO STAGE FULL FREE-LIFT

12 MAST-THREE STAGE FULL FREE-LIFT

13 OPTIONS

14 FIELD CONVERSION KITS

15 NUMERICAL INDEX

This Parts Manual is divided into 15 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.
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TABLE OF CONTENTS

DESCRIPTION PAGE
A
ACCUMULATOR ............................................................................................................................................. 13-18
ADD-ON OPTION KITS ................................................................................................................................... 14-2
AIR CLEANER
GM 4.3L - GASOLINE AND LPG (→ S/N G004V03075E) ......................................................................... 3-2
GM 4.3L - GASOLINE AND LPG (S/N G004V03076E →) ......................................................................... 3-4
AIR FILTER ..................................................................................................................................................... 3-7
ARMREST ASSEMBLY
MINI-LEVER MODULES - SEMI-SUSPENSION SEAT WITH HIP RESTRAINTS ..................................... 1-44
MINI-LEVER MODULES ............................................................................................................................. 1-46
AUDIBLE ALARM KITS ................................................................................................................................... 14-3
AUXILIARY HOSES ........................................................................................................................................ 9-70
AUXILIARY TUBE EXTENSION KIT ............................................................................................................... 14-9
AUXILIARY TUBE EXTENSIONS
THREE STAGE FULL FREE-LIFT - WITHOUT QUICK DISCONNECT
FITTINGS (S/N B588V02595G →) (S/N B589V03132G →) ..................................................................... 12-40
THREE STAGE FULL FREE-LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B588V02595G →) (S/N B589V03132G →) ..................................................................... 12-42
THREE STAGE FULL FREE-LIFT - E-HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B588V02595G →) (S/N B589V03132G →) ..................................................................... 12-44
THREE STAGE FULL FREE-LIFT (→ S/N B588V02594G) (→ S/N B589V03131G) ............................... 12-36
TWO STAGE FULL FREE- LIFT - WITHOUT QUICK DISCONNECT FITTINGS (S/N B590V01652G →)
(S/N B591V01652G →) .............................................................................................................................. 11-34
TWO STAGE FULL FREE- LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B590V01652G →) (S/N B591V01652G →) ..................................................................... 11-36
TWO STAGE FULL FREE- LIFT - E-HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B590V01652G →) (S/N B591V01652G →) ..................................................................... 11-38
TWO STAGE FULL FREE-LIFT - THREE FUNCTION (→ S/N B590V01651G) (→ S/N B591V01651G)
.................................................................................................................................................................... 11-32
TWO STAGE LIMITED FREE LIFT - WITHOUT QUICK DISCONNECT
FITTINGS (S/N B586V01930G →) (S/N B587V02097G →) ..................................................................... 10-26
TWO STAGE LIMITED FREE LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B586V01930G →) (S/N B587V02097G →) ..................................................................... 10-28
TWO STAGE LIMITED FREE LIFT - E-HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B586V01930G →) (S/N B587V02097G →) ..................................................................... 10-30
TWO STAGE LIMITED FREE-LIFT (→ S/N B586V01929G) (→ S/N B587V02096G) ............................. 10-22
TWO STAGE LIMITED FREE-LIFT - INTEGRAL SIDE-SHIFT CARRIAGE (→ S/N B586V01929G)
(→ S/N B587V02096G) .............................................................................................................................. 10-24

B
BACK-UP ALARM
COUNTERWEIGHT MOUNTED (→ 5/2009) ............................................................................................. 13-10
OVERHEAD GUARD MOUNTED (5/2009 →) ........................................................................................... 13-12
BOLT-ON FENDERS ...................................................................................................................................... 13-2
BRAKE AND INCHING PEDAL CONVERSION .............................................................................................. 14-2
BRAKE ASSEMBLY
S100-120FT, S120FTS, S120FTPRS - DRY BRAKE ................................................................................. 8-4
S80FT, S80-100FTBCS - DRY BRAKE ...................................................................................................... 8-2

©2011 HYSTER COMPANY See Service Manual i

for service procedures.
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TABLE OF CONTENTS (continued)

DESCRIPTION PAGE
BRAKE COOLING SYSTEM
SINGLE AND DUAL PEDAL - WET BRAKE (→ S/N G004V01514D) ....................................................... 8-26
SINGLE AND DUAL PEDAL - WET BRAKE (S/N G004V01515D →) ....................................................... 8-28
BRAKE LINKAGE
DUAL PEDAL - DRY BRAKE ...................................................................................................................... 8-10
DUAL PEDAL - WET BRAKE ...................................................................................................................... 8-18
SINGLE PEDAL - DRY BRAKE .................................................................................................................. 8-6
SINGLE PEDAL - WET BRAKE .................................................................................................................. 8-14
BRAKE MASTER CYLINDER ASSEMBLY ..................................................................................................... 8-21

C
CAMSHAFT AND OIL PAN
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-52
CARRIAGE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-32
TWO STAGE FULL FREE-LIFT - S80-120FT ............................................................................................. 11-30
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-20
CARRIER ASSEMBLY
DRY BRAKE ................................................................................................................................................ 6-20
COIL ASSEMBLY
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-55
CONTROL LEVER LABELS ............................................................................................................................ 1-58
COUNTERWEIGHT ........................................................................................................................................ 1-18
COWL MOUNT ................................................................................................................................................ 1-15
CYLINDER BLOCK
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-42
CYLINDER HEAD
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-46

D
DIFFERENTIAL
DRY BRAKE ................................................................................................................................................ 6-14
WET BRAKE ............................................................................................................................................... 6-16
DISTRIBUTOR ASSEMBLY ............................................................................................................................ 4-56
DRIVE AXLE
DRY BRAKE ................................................................................................................................................ 6-2
DRIVE AXLE AND ATTACHING PARTS
WET BRAKE (→ S/N G004V01514D) ....................................................................................................... 6-6
WET BRAKE (S/N G004V01515D →) ....................................................................................................... 6-8
DRIVE AXLE HOUSING AND HUB
WET BRAKE ............................................................................................................................................... 6-10
DRIVE TIRE AND WHEEL .............................................................................................................................. 6-24

E
E-HYDRAULIC CONTROL CONVERSION KITS
ELECTRICAL SYSTEM
COWL, ELECTRONIC HYDRAULIC - WITH OPERATOR PRESENCE SYSTEM .................................... 4-16
COWL, MANUAL HYDRAULIC - WITH OPERATOR PRESENCE SYSTEM ............................................. 4-18
COWL, WITHOUT OPERATOR PRESENCE SYSTEM ............................................................................. 4-14
ENGINE, GM 4.3L, GASOLINE AND LPG .................................................................................................. 4-6

ii See Service Manual ©2011 HYSTER COMPANY

for service procedures.
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TABLE OF CONTENTS (continued)

DESCRIPTION PAGE
ENGINE, GM 4.3L, GS AND LPS ............................................................................................................... 4-10
LOAD WEIGH ............................................................................................................................................. 4-24
MAST .......................................................................................................................................................... 4-22
RIGHT HAND CHASSIS ............................................................................................................................. 4-4
TRANSMISSION ......................................................................................................................................... 4-20
ELECTRONIC CONTROL LEVERS
MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) - DATE CODE 0725 THROUGH 0743 ............... 4-34
MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) - DATE CODE 0744 ........................................... 4-42
MINI-LEVER MODULES - DATE CODE 0724 ............................................................................................ 4-30
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0725 THROUGH 0743 ............................ 4-32
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0744 ......................................................... 4-38
ELECTRONIC CONTROL VALVE
AUXILIARY ONE SECTION - THREE, FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ............... 9-52
AUXILIARY ONE SECTION - THREE, FOUR AND FIVE FUNCTION (S/N G004V04329G →) ............... 9-54
AUXILIARY TWO SECTION - FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ............................. 9-56
AUXILIARY TWO SECTION - FOUR AND FIVE FUNCTION (S/N G004V04329G →) ............................. 9-58
LIFT AND LOWER - THREE, FOUR, AND FIVE FUNCTION .................................................................... 9-46
OUTLET SECTION - THREE, FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ............................ 9-60
OUTLET SECTION - THREE, FOUR AND FIVE FUNCTION (S/N G004V04329G →) ............................ 9-62
TILT SECTION - THREE, FOUR, AND FIVE FUNCTION .......................................................................... 9-50
ELECTRONIC CONTROL VALVE ASSEMBLY
FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ............................................................................. 9-42
FOUR AND FIVE FUNCTION (S/N G004V04329G →) ............................................................................. 9-44
THREE FUNCTION (→ S/N G004V04328G) ............................................................................................. 9-38
THREE FUNCTION (S/N G004V04329G →) ............................................................................................. 9-40
ELECTRONIC HYDRAULIC POPPET VALVE
THREE, FOUR AND FIVE FUNCTION ....................................................................................................... 9-48
ELECTRONIC MINI LEVER LABELS
AUXILIARY DUAL FUNCTION ................................................................................................................... 1-56
AUXILIARY SINGLE FUNCTION ................................................................................................................ 1-54
ENGINE ASSEMBLY
GM 4.3L, GASOLINE AND LPG - SHEET 1 OF 3 ...................................................................................... 2-32
GM 4.3L, GASOLINE AND LPG - SHEET 2 OF 3 ...................................................................................... 2-36
GM 4.3L, GASOLINE AND LPG - SHEET 3 OF 3 ...................................................................................... 2-40
ENGINE COOLING SYSTEM
WITH BASIC TRANSMISSION AND DRY BRAKES (→ 11/2006) ............................................................ 2-8
WITH BASIC TRANSMISSION AND DRY BRAKES (11/2006 →) ............................................................ 2-12
WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (11/2006 →) ............................. 2-20
WITH EXTERNAL OIL COOLER AND WITH ELECTRONIC TRANSMISSION - OR WITH WET
BRAKES (→ 11/2006) ................................................................................................................................ 2-16
ENGINE MOUNT
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-30
EXHAUST SYSTEM
GM 4.3L, GASOLINE AND LPG - WITH CATALYTIC CONVERTER ......................................................... 2-2
EXHAUST WRAPS
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-6

©2011 HYSTER COMPANY See Service Manual iii

for service procedures.
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TABLE OF CONTENTS (continued)

DESCRIPTION PAGE
F
FAN MOUNT ASSEMBLY
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-24
FIRE EXTINGUISHER .................................................................................................................................... 13-9
FLOORPLATES AND COVERS
→ S/N G004V03201F EXC. 03150, 03157, 03175-03176, 03180-03184, 03189 ..................................... 1-8
S/N G004V03202F → INC. 03150, 03157, 03175-03176, 03180-03184, 03189 ....................................... 1-12
FLYWHEEL AND HOUSING
GM 4.3L, GASOLINE AND LPG (→ S/N G004V02834E (ONE SPEED WITH WET BRAKE))
(→ S/N G004V02844E INC. 02874-02877, 02879-02880, 02882-02883, 02891, 02894-02896, 02898,
02901-02902 (ONE SPEED WITH DRY BRAKE))
(→ S/N G004V02842E (TWO SPEED WITH DRY BRAKE))
(→ S/N G004V02844E (TWO SPEED WITH WET BRAKE)) .................................................................... 2-26
GM 4.3L, GASOLINE AND LPG (S/N G004V02835E → (ONE SPEED WITH WET BRAKES))
(S/N G004V02845E → EXC. 02874-02877, 02879-02880, 02882-02883, 02891, 00289 (ONE SPEED
WITH DRY BRAKE)) (S/N G004V00284E → (TWO SPEED WITH DRY BRAKE))
(S/N G004V02847E → (TWO SPEED WITH WET BRAKE)) .................................................................... 2-28
FORK
POLISHED WITH FULL BOTTOM TAPER HOOK TYPE ........................................................................... 1-50
STANDARD TAPER HOOK TYPE - CLASS III ........................................................................................... 1-48
STANDARD TAPER HOOK TYPE - CLASS IV .......................................................................................... 1-49
FORWARD CLUTCH
SINGLE SPEED TRANSMISSION (→ S/N G004V02079E) ...................................................................... 5-32
SINGLE SPEED TRANSMISSION (S/N G004V02080E →) ...................................................................... 5-34
FORWARD CLUTCH, HIGH
DUAL SPEED TRANSMISSION (→ S/N G004V02223E) .......................................................................... 5-36
DUAL SPEED TRANSMISSION (S/N G004V02224E →) .......................................................................... 5-38
FORWARD CLUTCH, LOW
DUAL SPEED TRANSMISSION (→ S/N G004V02223E) .......................................................................... 5-40
DUAL SPEED TRANSMISSION (S/N G004V02224E →) .......................................................................... 5-42
FREE-LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-20
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-24
TWO STAGE FULL FREE-LIFT - S80-120FT (→ 6/2009) ......................................................................... 11-18
TWO STAGE FULL FREE-LIFT - S80-120FT (6/2009 →) ......................................................................... 11-22
FUEL SYSTEM
GM 4.3L, GASOLINE .................................................................................................................................. 3-8
GM 4.3L, LPG ............................................................................................................................................. 3-12
FULL SUSPENSION SEAT
MANUAL AND ELECTRO-HYDRAULIC - SWIVEL AND NON-
SWIVEL (S/N G004V04680H → EXC. 04683) ........................................................................................... 1-38
SHEET 2 OF 2 (S/N G004V04680H → EXC. 04683) ................................................................................ 1-42
WITH AND WITHOUT ELECTRONIC CONTROLS - WITH LIMITED BACK
TILT (→ S/N G004V04679H INC. 04683) .................................................................................................. 1-34
FULL SUSPENSION SWIVEL SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683) ....................... 1-36

iv See Service Manual ©2011 HYSTER COMPANY

for service procedures.
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TABLE OF CONTENTS (continued)

DESCRIPTION PAGE
G
GEAR PUMP
→ 12/2009 .................................................................................................................................................. 9-10
1/2010 → .................................................................................................................................................... 9-12
GM LPG REGULATOR DRAIN KIT ................................................................................................................ 13-16

H
HAND LEVERS
FOUR FUNCTION - WITH DETENTED LEVERS ....................................................................................... 9-18
FOUR FUNCTION - WITHOUT DETENTED LEVERS ............................................................................... 9-20
THREE FUNCTION - WITH DETENTED LEVERS ..................................................................................... 9-14
THREE FUNCTION - WITHOUT DETENTED LEVERS ............................................................................. 9-16
HEADER HOSE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-28
TWO STAGE FULL FREE-LIFT - S80-120FT ............................................................................................. 11-26
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-14
HEADER HOSE CONVERSION KITS
HOIST HOSE AND ATTACHING PARTS ....................................................................................................... 9-73
HOOD ASSEMBLY
→ S/N G004V04643H ................................................................................................................................ 1-2
S/N G004V04644H → ................................................................................................................................ 1-4
HYDRAULIC FILTER ...................................................................................................................................... 9-6
HYDRAULIC OIL COOLER ............................................................................................................................. 9-8
HYDRAULIC SUPPLY AND RETURN ............................................................................................................ 9-2

I
IMPACT SENSOR ........................................................................................................................................... 4-60
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-6
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-4
INNER MAST AND FREE-LIFT
TWO STAGE FULL FREE-LIFT - S80-120FT (→ 6/2009) ......................................................................... 11-6
TWO STAGE FULL FREE-LIFT - S80-120FT (6/2009 →) ......................................................................... 11-10
INSTRUMENT CLUSTER ............................................................................................................................... 4-57
INTEGRAL SIDE-SHIFT
THREE STAGE FULL FREE-LIFT - S80FT ................................................................................................ 13-34
TWO AND THREE STAGE FULL FREE-LIFT - S100-120FT ..................................................................... 13-40
TWO STAGE FULL FREE-LIFT - S80FT .................................................................................................... 13-28
TWO STAGE LIMITED FREE-LIFT - S80-120FT ....................................................................................... 13-20
INTEGRAL SIDE-SHIFT CARRIAGE
THREE STAGE FULL FREE-LIFT - 1067 MM (42 IN.) CLASS III .............................................................. 13-36
THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III .............................................................. 13-38
THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV .............................................................. 13-44
TWO STAGE FULL FREE-LIFT - 1067 MM (42 IN.) CLASS III .................................................................. 13-30
TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III .................................................................. 13-32
TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV ................................................................. 13-42
TWO STAGE LIMITED FREE-LIFT - 1067 MM (42 IN.) CLASS III ............................................................ 13-22
TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS III ............................................................ 13-24
TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS IV ............................................................ 13-26

©2011 HYSTER COMPANY See Service Manual v

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-8

L
LABELS
EXTERIOR .................................................................................................................................................. 1-62
INTERIOR ................................................................................................................................................... 1-60
LIGHT KITS ..................................................................................................................................................... 14-3
LOAD BACKREST EXTENSION ..................................................................................................................... 1-52
LPG TANK BRACKET
SWING OUT (→ S/N G004V03216F (NON BCS)) (→ S/N G004V03117E (BCS)) .................................. 3-22
SWING OUT (S/N G004V03217F → (NON BCS)) (S/N G004V03118E → (BCS)) .................................. 3-24
SWING OUT/ DROP DOWN (→ S/N G004V03038E (NON BCS)) (→ S/N G004V03035E (BCS)) ......... 3-28
SWING OUT/DROP DOWN (S/N G004V03039E → (NON BCS)) (S/N G004V03036E → (BCS)) .......... 3-32

M
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-12
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-6
MAIN LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-16
TWO STAGE FULL FREE-LIFT - S80-120FT ............................................................................................. 11-14
TWO STAGE LIMITED FREE-LIFT - S80FT .............................................................................................. 10-10
TWO STAGE LIMITED FREE-LIFT - S100-120FT ..................................................................................... 10-12
MANUAL CONTROL VALVE
AUXILIARY ONE AND TWO SECTION - THREE AND FOUR
FUNCTION (→ S/N G004V02934E (THREE FUNCTION)) (→ S/N G004V02942E (FOUR FUNCTION))
.................................................................................................................................................................... 9-32
AUXILIARY ONE AND TWO SECTION - THREE AND FOUR
FUNCTION (S/N G004V02935E → (THREE FUNCTION))
(S/N G004V02943E → (FOUR FUNCTION)(FOUR FUNCTION)) ............................................................ 9-34
LIFT AND TILT - THREE AND FOUR FUNCTION (→ S/N G004V02934E (THREE FUNCTION))
(→ S/N G004V02942E (FOUR FUNCTION)) ............................................................................................. 9-26
LIFT AND TILT - THREE AND FOUR FUNCTION (S/N G004V02935E → (THREE FUNCTION))
(S/N G004V02943E → (FOUR FUNCTION)) ............................................................................................. 9-28
LIFT AND TILT - THREE AND FOUR FUNCTION (S/N G004V04302G →) ............................................. 9-30
OUTLET SECTION - THREE, FOUR, AND FIVE FUNCTION ................................................................... 9-36
MANUAL CONTROL VALVE ASSEMBLY
THREE AND FOUR FUNCTION ................................................................................................................. 9-22
MANUAL CONTROL VALVE LOCKOUT GROUP .......................................................................................... 9-24
MANUAL HYDRAULIC CONTROL CONVERSION KITS ............................................................................... 14-4
MINI LEVER MODULE LABELS
HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-64
MINI-LEVER CONTROLS
WITH ARMREST - THREE FUNCTION (S/N G004V04680H → EXC. 04683) ......................................... 4-46
WITH ARMREST - FOUR FUNCTION (S/N G004V04680H → EXC. 04683) ........................................... 4-48
WITH ARMREST - FIVE FUNCTION (S/N G004V04680H → EXC. 04683) .............................................. 4-50
MIRROR .......................................................................................................................................................... 13-7
REAR MOUNTED ....................................................................................................................................... 13-8

vi See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE
MISCELLANEOUS .......................................................................................................................................... 14-11
MONOTROL PEDAL ASSEMBLY ................................................................................................................... 3-38

N
NON SUSPENSION SEAT
WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683) .......................................... 1-24
NON-SUSPENSION SEAT
→ S/N G004V04679H INC. 04683 ............................................................................................................. 1-22

O
OIL PUMP
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-56
OUTER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-2
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-2
OUTER MAST AND MAIN LIFT
TWO STAGE FULL FREE-LIFT - S80-120FT ............................................................................................. 11-2
OVERHEAD GUARD ...................................................................................................................................... 1-20

P
PARKING BRAKE ASSEMBLY ....................................................................................................................... 8-24
POWER DISTRIBUTION MODULE
→ S/N G004V01735D ................................................................................................................................ 4-26
S/N G004V01736D → ................................................................................................................................ 4-28
PRE-CLEANER AND MOUNT ........................................................................................................................ 3-6
PRESSURE REGULATOR ............................................................................................................................. 13-14

R
REGULATOR
LPG ............................................................................................................................................................. 3-20
REMOTE KEY SWITCH .................................................................................................................................. 4-52
REPLACEMENT KITS
REVERSE CLUTCH
DUAL SPEED TRANSMISSION (→ S/N G004V02223E) .......................................................................... 5-48
DUAL SPEED TRANSMISSION (S/N G004V02224E →) .......................................................................... 5-50
SINGLE SPEED TRANSMISSION (→ S/N G004V02079E) ...................................................................... 5-44
SINGLE SPEED TRANSMISSION (S/N G004V02080E →) ...................................................................... 5-46

S
SEALED ALTERNATOR AND MOUNTING
GM 4.3L ....................................................................................................................................................... 4-53
SEAT CONVERSION KITS ............................................................................................................................. 14-2
SEMI-SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (→ 7/2006) ................................................................ 1-26
WITH AND WITHOUT ELECTRONIC CONTROLS (7/2006 ↔ S/N G004V04679H) ................................ 1-28
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683) ....................... 1-32
STARTER
GM 4.3L, GS AND LPS ............................................................................................................................... 4-54
STEER AXLE .................................................................................................................................................. 7-8
STEER CYLINDER ......................................................................................................................................... 7-14

©2011 HYSTER COMPANY See Service Manual vii

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE
STEER TIRES AND WHEELS ........................................................................................................................ 7-16
STEERING COLUMN AND ATTACHING PARTS .......................................................................................... 7-2
STEERING COLUMN ASSEMBLY ................................................................................................................. 7-4
STEERING CONTROL UNIT .......................................................................................................................... 7-6
STEERING LINES ........................................................................................................................................... 7-12
STROBE LIGHT
→ S/N G004V02783E EXC. 02746, 02754-02758 ..................................................................................... 13-4
LED (S/N G004V02784E → INC. 02746, 02754-02758) ........................................................................... 13-6

T
THROTTLE BODY ASSEMBLY
GM 4.3L LPG (S/N G004V04608H → INC. 04572) ................................................................................... 3-18
GM 4.3L, LPG (→ S/N G004V04607H EXC. 04572) ................................................................................. 3-16
THROTTLE BODY ASSEMBLY AND FUEL RAIL
GM 4.3L, GASOLINE .................................................................................................................................. 3-10
THROTTLE PEDAL AND ATTACHING PARTS ............................................................................................. 3-36
TILT CYLINDER .............................................................................................................................................. 9-66
TILT CYLINDER INSTALLATION ................................................................................................................... 9-64
TILT HOSES .................................................................................................................................................... 9-68
TORQUE CONVERTER
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 5-4
TRANSMISSION
DUAL SPEED, THREE PIECE HOUSING - SHEET 1 OF 2 (→ S/N G004V02228E (WET BRAKE))
(→ S/N G004V02223E DRY BRAKE) ........................................................................................................ 5-52
DUAL SPEED, THREE PIECE HOUSING - SHEET 2 OF 2 (→ S/N G004V00228E (WET BRAKE))
(→ S/N G004V02223E DRY BRAKE) ........................................................................................................ 5-56
DUAL SPEED, THREE PIECE HOUSING, SHEET 1 OF
2 (S/N G004V02224E ↔ S/N G004V02842E DRY BRAKE)
(S/N G004V02229E ↔ S/N G004V02846E WET BRAKE) ........................................................................ 5-58
DUAL SPEED, THREE PIECE HOUSING, SHEET 2 OF
2 (S/N G004V02224E ↔ S/N G004V02842E DRY BRAKE)
(S/N G004V02229E ↔ S/N G004V02846E WET BRAKE) ........................................................................ 5-61
DUAL SPEED, TWO PIECE HOUSING - SHEET 1 OF 2 (S/N G004V02843E → (DRY BRAKE))
(S/N G004V02847E → (WET BRAKE)) ..................................................................................................... 5-64
DUAL SPEED, TWO PIECE HOUSING - SHEET 2 OF 2 (S/N G004V02843E → (DRY BRAKE))
(S/N G004V02847E → (WET BRAKE)) ..................................................................................................... 5-68
SINGLE SPEED, THREE PIECE HOUSING - SHEET 1 OF 2 (→ S/N G004V02079E EXC. 1698) ......... 5-14
SINGLE SPEED, THREE PIECE HOUSING - SHEET 2 OF 2 (→ S/N G004V02079E EXC. 1698) ......... 5-18
SINGLE SPEED, THREE PIECE HOUSING - SHEET 1 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698)
.................................................................................................................................................................... 5-20
SINGLE SPEED, THREE PIECE HOUSING - SHEET 2 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698)
.................................................................................................................................................................... 5-24
SINGLE SPEED, TWO PIECE HOUSING - SHEET 1 0F 2 (9/2007 →) .................................................... 5-26
SINGLE SPEED, TWO PIECE HOUSING - SHEET 2 0F 2 (9/2007 →) .................................................... 5-30
TRANSMISSION CONTROL VALVE ASSEMBLY
→ PENDING PER ECN 104793 ................................................................................................................ 5-72
PENDING PER ECN 104793 → ................................................................................................................ 5-74

viii See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE
TRANSMISSION COOLING
GM 4.3L, GASOLINE AND LPG, WITH INTERNAL OIL COOLER - BASIC POWERSHIFT
TRANSMISSION (→ S/N G004V04081F) .................................................................................................. 5-6
GM 4.3L, LPG, WITH INTERNAL OIL COOLER - BASIC POWERSHIFT
TRANSMISSION (S/N G004V04082F →) .................................................................................................. 5-8
WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (→ S/N G004V04081F) ............ 5-10
WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (S/N G004V04082F →) ............ 5-12
TRANSMISSION MOUNT ............................................................................................................................... 5-3

V
VALVE COVER AND INLET MANIFOLD
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-48
VENT LINE GROUP ........................................................................................................................................ 9-72

W
WET BRAKES ................................................................................................................................................. 6-22
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER - MANUAL, WITH OPERATOR PRESENCE ..................... 4-126
COWL WITH FORWARD/REVERSE LEVER - WITHOUT RETURN TO SET TILT .................................. 4-130
COWL WITH MONOTROL PEDAL - WITH RETURN TO SET TILT .......................................................... 4-134
COWL WITH MONOTROL PEDAL - WITH HYDRAULIC PUMP SOLENOID ............................................ 4-138
ELECTRONIC CONTROL VALVE - THREE FUNCTION ........................................................................... 4-142
ELECTRONIC CONTROL VALVE - FOUR FUNCTION ............................................................................. 4-144
ELECTRONIC CONTROL VALVE - FIVE FUNCTION ............................................................................... 4-146
ENGINE - GM 4.3L, GASOLINE (→ S/N G004V03165E) .......................................................................... 4-104
ENGINE - GM 4.3L, GASOLINE (S/N G004V03166E ↔ S/N G004V04601H EXC. 04572) ..................... 4-106
ENGINE - GM 4.3L, LPG (→ S/N G004V02853E) ..................................................................................... 4-114
ENGINE - GM 4.3L, LPG (S/N G004V02854E ↔ S/N G004V04601H EXC. 04572) ................................. 4-116
JOYSTICK ................................................................................................................................................... 4-148
LEFT HAND CHASSIS - GM 4.3L, GASOLINE (→ S/N G004V04601H EXC. 04572) .............................. 4-94
LEFT HAND CHASSIS - GM 4.3L GASOLINE (SERIES 2010) (S/N G004V04608H → INC. 04572) ....... 4-96
LEFT HAND CHASSIS - GM 4.3L, LPG (→ S/N G004V04607H EXC. 04572) ......................................... 4-98
LEFT HAND CHASSIS - GM 4.3L LPG (2010 SERIES)(WITH PREMIUM LOW FUEL
SENSOR) (S/N G004V04608H → INC. 04572) ......................................................................................... 4-100
LEFT HAND CHASSIS - GM 4.3L LPG (2010 SERIES)(WITHOUT PREMIUM LOW FUEL
SENSOR) (S/N G004V04608H → INC. 04572) ......................................................................................... 4-102
LIGHTS (→ S/N G004V01639D) ................................................................................................................ 4-154
LIGHTS (S/N G004V01640D ↔ 6/2007) .................................................................................................... 4-156
LIGHTS (6/2007 →) ................................................................................................................................... 4-158
LOW FUEL SENSOR .................................................................................................................................. 4-160
RIGHT HAND CHASSIS - GM 4.3L (→ 8/2006) ........................................................................................ 4-62
RIGHT HAND CHASSIS - GM 4.3L (8/2006 ↔ S/N G004V02853E (LPG))
(8/2006 ↔ S/N G004V03165E (GASOLINE)) ............................................................................................ 4-68
RIGHT HAND CHASSIS - GM 4.3L (S/N G004V02854E ↔ S/N G004V04328G (LPG))
(S/N G004V03166E ↔ S/N G004V04328G (GASOLINE)) ........................................................................ 4-74
RIGHT HAND CHASSIS - GM 4.3L (S/N G004V04329G ↔ PENDING PER ECN 10551437) ................. 4-80
RIGHT HAND CHASSIS - GM 4.3L (PENDING PER ECN 10551437 →) ................................................. 4-86
SEALED ALTERNATOR - GM 4.3L ............................................................................................................ 4-123
SEAT JUMPER (→ PENDING PER ECN 10551437) ................................................................................ 4-92

©2011 HYSTER COMPANY See Service Manual ix

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE
TRANSMISSION - SINGLE SPEED ........................................................................................................... 4-150
TRANSMISSION - DUAL SPEED ............................................................................................................... 4-152
WIRE HARNESS (ENGINE)
GM 4.3L GASOLINE (2010 SERIES) (S/N G004V04608H → INC. 04572) ............................................... 4-110
GM 4.3L LPG (2010 SERIES) (S/N G004V04608H → INC. 04572) .......................................................... 4-120
WORK, REAR DRIVE, AND BRAKE/TAIL LIGHTS ........................................................................................ 4-58

x See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ABBREVIATIONS QUICK REFERENCE SHEET

Listed below are abbreviations used in parts manuals to denote the following expressions:
spacer
TERM DEFINITION TERM DEFINITION
Amp Amperes FRE Freezer Environment
AR As Required in. inches
BDI Battery Discharge Indicators LPG Liquefied Petroleum Gas
BWI Brush Wear Indicator MAP Manifold Absolute Pressure
CE Communicator End mm millimeters
CRE Corrosive Environment MSTS Microprocessor Spark Timing System
D/B Date Break NPT National Pipe Threads
dbA Decibel "A" Scale O/S Oversize
DE Drive End PTO Power Take Off
ECH Empty Container Handler RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High S/N Serial Number
Stacking TMM Truck Management Module
ECH-4 Empty Container Handler - 4 High UL Type D Diesel-Powered Safety Rating
Stacking
UL Type DS Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High
Stacking UL Type E Battery-Powered Safety Rating

ECH-6 Empty Container Handler - 6 High UL Type EE Battery-Powered Safety Rating

Stacking UL Type ES Battery-Powered Safety Rating
ECH-7 Empty Container Handler - 7 High UL Type G Gasoline-Powered Safety Rating
Stacking UL Type GS Gasoline-Powered Safety Rating
ECM Electronic Control Module UL Type LP Gas-Powered Safety Rating
ECN Engineering Change Notice UL Type LPS LP Gas-Powered Safety Rating
EEPROM Electrically Erasable Programmable U/S Undersize
Read Only Memory
UL Underwriters Laboratory
EPA US Environmental Protection Agency
V Volts
EPROM Electrically Programmable Read Only
Memory

©2011 HYSTER COMPANY See Service Manual xi

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HOW TO USE THE ILLUSTRATED PARTS MANUAL

This parts manual describes and illustrates assemblies, The different constructions are indicated by keys and
subassemblies, and detail parts needed for service footnotes. The callouts correspond to descriptions
replacement. found on the next page.

xii See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HOW TO FIND THE DESIRED PART NUMBER

WHEN THE PART NUMBER AND THE NEXT subparts of assemblies. In the example on the
HIGHER ASSEMBLY IS NOT KNOWN: previous page, BEARING CAP (Item 2) is a
1. Determine the function and application of the part subpart of the major assembly CASE.
required. Turn to the Sections Page. Choose the 9. Quantities shown are for one assembly. The
general area of reference most likely to include the quantities of the subpart BEARING CAP are
part. indicated as two and two. This means two per
2. Turn to the section you chose. Use the Section CASE assembly.
Table of Contents to determine the assembly 10. Serial number breaks identify the most current
which would normally contain the part required. parts information and are shown as follows:
Then locate the part on the assembly breakdown → S/N D001H2628
page. Indicates last serial number affected.
S/N D001H2629 →
WHEN THE PART NUMBER IS NOT KNOWN
Indicates the first serial number affected.
AND THE NEXT HIGHER ASSEMBLY IS
S/N D001H1553 ↔ S/N D001H3291
KNOWN:
Indicates a range of serial numbers affected.
3. Determine the assembly the required part is used
on. Turn to the Table of Contents (Page i). ECN numbers for pending serial numbers are
shown to allow for the inclusion of the most current
4. Locate the assembly the required part is used on
parts information and are identified as follows:
and turn to the page indicated for that assembly.
→ S/N Pending Per ECN 63243
Then locate the part on the assembly breakdown
Indicates a pending serial number for last unit
page.
affected.
WHEN THE PART NUMBER IS KNOWN: S/N Pending Per ECN 63243 →
5. Use the Numerical Index (Page 15-1) to find the Indicates a pending serial number for first unit
part number. Turn to the page listed and locate the affected.
part as indicated by the item number. Date breaks are used to indicate when a change
GENERAL: occurred but a subsequent serial number break
was not recorded. This is an arbitrary date usually
The assembly breakdowns include part numbers, based on the ECN release and are identified as
descriptions, quantities required, keys and follows:
footnotes to help in selecting correct parts. → D/B 3/00
6. Parts Supersession Information. Part numbers that Indicates that a change occurred sometime
have this history will be displayed in the parts list within that month for the item affected.
in the order that they were superseded (from oldest D/B 3/00 →
to newest). The superseded part numbers will be Indicates that a change occurred sometime
shown with a line through them. within that month for the item affected.
D/B 3/00 ↔ D/B 4/00
Five periods in the PART NO. column (. . . . .)
Indicates a range of production dates of the item
indicate that the part is either Not Serviced
affected.
Separately or there is a reference to another figure.
A figure reference is denoted by a pointing hand Contact your local dealer for Hyster lift trucks for
followed by a figure number in the DESCRIPTION serial number information for items with a ECN or
column (FFigure 10) a date break.
7. Keys are used to show two or more similar
ORDERING PARTS:
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" When ordering replacement parts, give the unit serial
and the corresponding quantity column to find the number, part number, name of part and quantity
required parts. Two periods in the QTY column (..) required.
indicate that the part is not used for that assembly.
8. Indented descriptions under the DESCRIPTION For any further information on parts, service, or
column are used to indicate assemblies and ordering, consult your local dealer for Hyster lift trucks.

©2011 HYSTER COMPANY See Service Manual xiii

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

SERIAL NUMBER SPECIFIC MANUALS

SERIAL NUMBER SPECIFIC INFORMATION SPECIAL PARTS INFORMATION (SPI)

This manual contains serial number specific parts NOTE: This lift truck may contain special content. Every
information. Every effort has been made to provide you effort has been made to reflect that information in this
a manual that reflects your fork lift truck as it was manual. The user is advised to refer to the special
manufactured. The serial number for your truck is content information that pertains to this specific serial
shown on the front cover of this manual. number truck.

Parts that are specific to your truck are identified in If your truck contains special content a Special Parts
bold lettering in the parts list. Parts that are not specific Information section is included as the last section of this
are in gray lettering. Entire figures that are not manual. Use the section table of contents to locate. This
applicable to your truck are completely grayed out, section contains parts lists and drawings for the special
these are also shown as grayed items in the Table of content added to the lift truck.
Contents. If an entire section was not applicable to your
truck it was not included in this publication. When possible a SPI icon ( ) will be placed in the parts
list denoting that the part number has been replaced by
Please note that it is possible that not all items specific a special equipment design part number. Please refer
to your truck will be shown in bold lettering. In this case to the SPI section for information on these parts. The
refer to the grayed items and the illustration for proper SPI icon in a table of contents is a quick reference
parts ordering. If a part still cannot be identified, please showing which figures are part of the SPI section.
consult your local dealer for Hyster lift trucks.

Refer to the "How To Use The Illustrated Parts Manual"

section for the basic use and functionality of this
manual.

xiv See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957, 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.

©2011 HYSTER COMPANY See Service Manual xv

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

IDENTIFICATION OF MAST SERIAL NUMBERS

(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.

LIFT EQUIPMENT IDENTIFICATION

1. Fork part number, capacity rating, plant code letter,
and date of manufacture are stamped
approximately six inches below the top of most
forks.
2. The carriage group number is stamped on the right
hand side of the top crossmember (pin type) or on
the back of the right hand end of the bottom
crossmember (hook type). A date code has two
letters in line with or below the carriage group
number.
3. The mast identification number has a unit code, a
letter indicating the plant of manufacture, and a
serial number. Underneath the production
sequence number is a four digit number that
indicates the carriage travel in millimeters.
4. Tilt and lift cylinder group numbers are stamped on
the cylinder shell.
Always refer to the group, serial, or part number
when ordering service parts.
Modification of masts and 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.

xvi See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

IDENTIFICATION OF ATTACHMENT AND SIDE-

SHIFT CARRIAGE SERIAL NUMBERS

(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.

©2011 HYSTER COMPANY See Service Manual xvii

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

PUBLICATIONS

Every new lift truck is provided with an OPERATING MANUALS with complete replacement part
MANUAL. This manual has information that the identification, are available at a nominal fee from your
operator must know for inspection and operation of the Hyster dealer to assist users in effectively maintaining
lift truck. Hyster lift trucks in a safe, useful condition. See the list
below for information on ordering specific publications
SERVICE MAINTENANCE MANUALS, which provide for this model lift truck.
service and overhaul procedures, and PARTS

PUBLICATION HYSTER PART NUMBER

Operating Manual........................................................................................................................ 1624733

Service Manual (Complete)......................................................................................................... 1624735

Parts Manual............................................................................................................................... 1624734

xviii See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

1 FRAME
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 1
FRAME

DESCRIPTION PAGE

ARMREST ASSEMBLY
MINI-LEVER MODULES - SEMI-SUSPENSION SEAT WITH HIP RESTRAINTS ..................................... 1-44
MINI-LEVER MODULES ............................................................................................................................. 1-46
CONTROL LEVER LABELS ............................................................................................................................ 1-58
COUNTERWEIGHT ........................................................................................................................................ 1-18
COWL MOUNT ................................................................................................................................................ 1-15
ELECTRONIC MINI LEVER LABELS
AUXILIARY DUAL FUNCTION ................................................................................................................... 1-56
AUXILIARY SINGLE FUNCTION ................................................................................................................ 1-54
FLOORPLATES AND COVERS
→ S/N G004V03201F EXC. 03150, 03157, 03175-03176, 03180-03184, 03189 ..................................... 1-8
S/N G004V03202F → INC. 03150, 03157, 03175-03176, 03180-03184, 03189 ....................................... 1-12
FORK
POLISHED WITH FULL BOTTOM TAPER HOOK TYPE ........................................................................... 1-50
STANDARD TAPER HOOK TYPE - CLASS III ........................................................................................... 1-48
STANDARD TAPER HOOK TYPE - CLASS IV .......................................................................................... 1-49
FULL SUSPENSION SEAT
MANUAL AND ELECTRO-HYDRAULIC - SWIVEL AND NON-
SWIVEL (S/N G004V04680H → EXC. 04683) ........................................................................................... 1-38
SHEET 2 OF 2 (S/N G004V04680H → EXC. 04683) ................................................................................ 1-42
WITH AND WITHOUT ELECTRONIC CONTROLS - WITH LIMITED BACK
TILT (→ S/N G004V04679H INC. 04683) .................................................................................................. 1-34
FULL SUSPENSION SWIVEL SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683) ....................... 1-36
HOOD ASSEMBLY
→ S/N G004V04643H ................................................................................................................................ 1-2
S/N G004V04644H → ................................................................................................................................ 1-4
LABELS
EXTERIOR .................................................................................................................................................. 1-62
INTERIOR ................................................................................................................................................... 1-60
LOAD BACKREST EXTENSION ..................................................................................................................... 1-52
MINI LEVER MODULE LABELS
HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-64
NON SUSPENSION SEAT
WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683) .......................................... 1-24
NON-SUSPENSION SEAT
→ S/N G004V04679H INC. 04683 ............................................................................................................. 1-22
OVERHEAD GUARD ...................................................................................................................................... 1-20
SEMI-SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (→ 7/2006) ................................................................ 1-26
WITH AND WITHOUT ELECTRONIC CONTROLS (7/2006 ↔ S/N G004V04679H) ................................ 1-28
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683) ....................... 1-32

©2011 HYSTER COMPANY See Service Manual 1-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HOOD ASSEMBLY (FIGURE 1-1)

(→ S/N G004V04643H)

1-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HOOD ASSEMBLY
(→ S/N G004V04643H)

ITEM PART NO. DESCRIPTION QTY

a 1643572 Hood ................................................................................................................... 1
b 1676400 Hood ................................................................................................................... 1
a 1643702 Hood (Vented) .................................................................................................... 1
b 1676401 Hood (Vented) .................................................................................................... 1
1 1616764 Hood ............................................................................................................... 1
1 1616768 Hood (Vented) ................................................................................................ 1
2 1544846 Hood Reinforcement ...................................................................................... 1
3 1608879 Capscrew ................................................................................................... 6
4 1585590 Bracket ....................................................................................................... 1
5 1582370 Bracket ....................................................................................................... 1
6 1527876 Capscrew ................................................................................................... 4
7 1580293 Plate ........................................................................................................... 1
8 1608877 Bracket ....................................................................................................... 1
9 1547971 Hinge .............................................................................................................. 2
10 302381 Dowel ......................................................................................................... 1
11 1600496 Stud ................................................................................................................ 2
12 1527880 Capscrew ....................................................................................................... 10
13 1534417 Capscrew ....................................................................................................... 6
14 329069 Nut .................................................................................................................. 4
15 1528906 Screw ............................................................................................................. 2
16 1580652 Seal ................................................................................................................ 1
17 1527878 Capscrew ....................................................................................................... 4
18 1527876 Capscrew ....................................................................................................... 2
19 1582286 Latch ............................................................................................................... 1
20 1582287 Handle ............................................................................................................ 1
21 329069 Nut ...................................................................................................................... 2
22 1347045 Fastener .............................................................................................................. 8
23 296032 Capscrew ............................................................................................................ 4
24 1460477 Nut ...................................................................................................................... 4
25 1561015 Grommet ............................................................................................................. 1
26 1527881 Capscrew ............................................................................................................ 2
27 1530243 Insert ................................................................................................................... 4
28 a 1584617 Striker Bolt .......................................................................................................... 1
28 b 1674131 Striker Bolt .......................................................................................................... 1
29 1583611 Capscrew ............................................................................................................ 2
30 a 1623905 Bracket ................................................................................................................ 1
30 b 1674030 Hood Support ...................................................................................................... 1
31 1563369 Ball Stud ............................................................................................................. 4
31 1606659 Ball Stud (Locking) .............................................................................................. 4
32 1563497 Gas Spring .......................................................................................................... 2
32 1610853 Gas Spring (Use with Locking Gas Spring) ........................................................ 1
32 1610854 Gas Spring (Locking) .......................................................................................... 1

FOOTNOTES:
a → PENDING PER ECN 105290 b PENDING PER ECN 105290 →

©2011 HYSTER COMPANY See Service Manual 1-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HOOD ASSEMBLY (FIGURE 1-2)

(S/N G004V04644H →)

1-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HOOD ASSEMBLY
(S/N G004V04644H →)

ITEM PART NO. DESCRIPTION QTY

c 4007719 Hood ................................................................................................................... 1
d 4016192 Hood ................................................................................................................... 1
b 4007720 Hood (Vented) .................................................................................................... 1
d 4016193 Hood ................................................................................................................... 1
1 b 4007549 Hood ............................................................................................................... 1
1 b 4007562 Hood (Vented) ................................................................................................ 1
1 d 4015888 Hood ............................................................................................................... 1
1 d 4016100 Hood ............................................................................................................... 1
2 1666732 Boot ............................................................................................................... 1
3 1580652 Seal ................................................................................................................ 1
4 1616379 Plug (Yellow) ................................................................................................. 2
5 1548618 Hinge .............................................................................................................. 2
6 1527880 Capscrew ...................................................................................................... 10
7 1585581 Bumper (Hood) ............................................................................................. 2
8 329069 Nut ................................................................................................................. 2
9 1387170 Latch .............................................................................................................. 1
10 1534417 Capscrew ...................................................................................................... 6
11 1676406 Seat Pan ........................................................................................................ 1
11 4025271 Hood Reinforcement (Alternate Part) ............................................................. 1
12 1608876 Reinforcement .......................................................................................... 1
13 1608877 Bracket ...................................................................................................... 2
14 364868 Nut ............................................................................................................. 8
15 1608879 Capscrew .................................................................................................. 6
16 1585590 Bracket ...................................................................................................... 1
17 1582370 Bracket ...................................................................................................... 1
18 1527876 Capscrew .................................................................................................. 4
19 1324360 Nut ............................................................................................................. 4
20 1672560 Plate ........................................................................................................... 1
21 1563497 Gas Spring ......................................................................................................... 1
22 1563369 Ball Stud ............................................................................................................ 2
23 329069 Nut ...................................................................................................................... 2
24 1563497 Gas Spring ......................................................................................................... 1
24 a 4011435 Gas Spring .......................................................................................................... 1
25 1563369 Ball Stud ............................................................................................................ 2
25 a 4011397 Ball Stud ............................................................................................................. 2
26 1600496 Stud .................................................................................................................... 2
27 296032 Capscrew ........................................................................................................... 4
28 1460477 Nut ...................................................................................................................... 4
29 1527881 Capscrew ........................................................................................................... 2
30 1674131 Striker Bolt ........................................................................................................ 1
31 1530243 Insert .................................................................................................................. 2
32 1674030 Hood Support .................................................................................................... 1
33 1583611 Capscrew ........................................................................................................... 2
34 1347045 Fastener ............................................................................................................. 8
35 1561015 Grommet ............................................................................................................ 1
36 1585592 Plug ..................................................................................................................... 1
257291 Adhesive ............................................................................................................ AR

©2011 HYSTER COMPANY See Service Manual 1-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a With locking hood-spring option.
b → PENDING PER ECN 10651101
c S/N G004V04661H ↔ PENDING PER ECN
10651101
d PENDING PER ECN 10651101 →

1-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 1-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FLOORPLATES AND COVERS (FIGURE 1-3)

(→ S/N G004V03201F EXC. 03150, 03157, 03175-03176, 03180-03184, 03189)

1-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FLOORPLATES AND COVERS

(→ S/N G004V03201F EXC. 03150, 03157, 03175-03176, 03180-03184, 03189)

ITEM PART NO. DESCRIPTION QTY

1 2065668 Cover (Steering Column) (Upper) ....................................................................... 1
2 2065666 Cover (Steering Column Lower) ...................................................................... 1
3 2071261 Capscrew ........................................................................................................... 5
4 c 1517420 Dash Panel ........................................................................................................ 1
4 a 1517421 Dash Panel ......................................................................................................... 1
5 1531001 Insert .................................................................................................................. 8
6 2027655 Screw ................................................................................................................. 2
7 2065667 Clip ..................................................................................................................... 4
8 1579837 Seal .................................................................................................................... 1
9 1530135 Grommet ............................................................................................................ 1
10 1583611 Capscrew ........................................................................................................... 21
11 2071595 Panel (Single Brake Pedal) .............................................................................. 1
11 2071596 Panel (Dual Brake Pedal) ................................................................................... 1
12 b 1527939 Panel (Rear) (LH) ............................................................................................... 1
12 1527940 Panel (Rear) (LH) ............................................................................................... 1
13 1618992 Plate ................................................................................................................... 1
14 2071262 Floormat ............................................................................................................ 1
15 1573774 Floorplate .......................................................................................................... 1
16 1530019 Screw .................................................................................................................. 6
17 1480237 Nut ...................................................................................................................... 21
18 1350215 Nut ...................................................................................................................... 5
19 1552710 Cover (LH Fender) ............................................................................................ 1
20 1540861 Panel (LH Front) ................................................................................................ 1
21 1585835 Capscrew ........................................................................................................... 3
22 1587567 Panel (LH) ........................................................................................................... 1
23 1544186 Plate (Tread) ...................................................................................................... 1
24 1544153 Locknut .............................................................................................................. 3
25 1564529 Seal .................................................................................................................... 2
26 1540871 Panel (RH Front) ............................................................................................... 1
27 1552712 Cover (RH Fender) ............................................................................................ 1
28 2073762 Screw ................................................................................................................. 1
29 1544188 Plate (Tread) ...................................................................................................... 1
30 1582072 Trim Seal ............................................................................................................ 2
31 1587569 Panel (RH) .......................................................................................................... 1
32 1567032 Panel (RH Rear) ................................................................................................. 1
33 b 1517656 Shield ................................................................................................................. 1
34 2071198 Seal (RH) ............................................................................................................ 1
35 2071197 Seal (LH) ............................................................................................................ 1
36 1597467 Cover (Radiator) ................................................................................................ 1
36 d 1600559 Cover (Radiator Box Car Special) ...................................................................... 1
36 e 1658244 Cover (Radiator Box Car Special) ...................................................................... 1
36 1598092 Cover ............................................................................................................. 1
36 d 1600513 Cover .............................................................................................................. 1
36 e 1658243 Cover .............................................................................................................. 1
37 1544937 Seal (LH) ........................................................................................................ 1
37 1544936 Seal (RH) ....................................................................................................... 1
38 2085604 Spacer ................................................................................................................ 2
39 1624917 Knob ................................................................................................................... 1
39 2078312 Knob .............................................................................................................. 2
40 2085894 Strap .............................................................................................................. 2

©2011 HYSTER COMPANY See Service Manual 1-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FLOORPLATES AND COVERS

(→ S/N G004V03201F EXC. 03150, 03157, 03175-03176, 03180-03184, 03189)

ITEM PART NO. DESCRIPTION QTY

41 2021395 Cap ..................................................................................................................... 2
42 1347045 Fastener ............................................................................................................. 4
43 1531558 Insert .................................................................................................................. 6
44 2056823 Tail Light Base (RH) ........................................................................................... 1
45 1586495 Capscrew ........................................................................................................... 4
46 1540643 Capscrew ........................................................................................................... 3
47 2069203 Cover .................................................................................................................. 1
48 2056822 Tail Light Base (LH) ............................................................................................ 1

FOOTNOTES:
a Electronic Hydraulics d → 9/2007
b Gasoline Trucks Only e 9/2007 →
c Manual Controls

1-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 1-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FLOORPLATES AND COVERS (FIGURE 1-4)

(S/N G004V03202F → INC. 03150, 03157, 03175-03176, 03180-03184, 03189)

1-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FLOORPLATES AND COVERS

(S/N G004V03202F → INC. 03150, 03157, 03175-03176, 03180-03184, 03189)

ITEM PART NO. DESCRIPTION QTY

1 2098330 Cover (Steering Column Upper) ...................................................................... 1
2 2065666 Cover (Steering Column Lower) ...................................................................... 1
3 2071261 Capscrew ........................................................................................................... 5
4 c 1517420 Dash Panel ........................................................................................................ 1
4 a 1517421 Dash Panel ......................................................................................................... 1
5 1531001 Insert .................................................................................................................. 8
6 2027655 Screw ................................................................................................................. 2
7 2065667 Clip ..................................................................................................................... 4
8 1579837 Seal .................................................................................................................... 1
9 1530135 Grommet ............................................................................................................ 1
10 1583611 Capscrew ........................................................................................................... 21
11 2071595 Panel (Single Brake Pedal) .............................................................................. 1
11 2071596 Panel (Dual Brake Pedal) ................................................................................... 1
12 b 1527939 Panel (Rear) (LH) ............................................................................................... 1
12 1527940 Panel (Rear) (LH) ............................................................................................... 1
13 1618992 Plate ................................................................................................................... 1
14 2071262 Floormat ............................................................................................................ 1
15 1573774 Floorplate .......................................................................................................... 1
16 1530019 Screw .................................................................................................................. 6
17 1480237 Nut ...................................................................................................................... 21
17 1480237 Nut (Alternate Part) ........................................................................................... 13
18 1350215 Nut ...................................................................................................................... 5
19 1552710 Cover (LH Fender) ............................................................................................ 1
20 1540861 Panel (LH Front) ................................................................................................ 1
21 1585835 Capscrew ........................................................................................................... 3
22 1587567 Panel (LH) ........................................................................................................... 1
23 1544186 Plate (Tread) ...................................................................................................... 1
24 1544153 Locknut .............................................................................................................. 3
25 1564529 Seal .................................................................................................................... 2
26 1540871 Panel (RH Front) ............................................................................................... 1
27 1552712 Cover (RH Fender) ............................................................................................ 1
28 2073762 Screw ................................................................................................................. 1
29 1544188 Plate (Tread) ...................................................................................................... 1
30 1582072 Trim Seal ............................................................................................................ 2
31 1587569 Panel (RH) .......................................................................................................... 1
32 1567032 Panel (RH Rear) ................................................................................................. 1
33 b 1517656 Shield ................................................................................................................. 1
34 2071198 Seal (RH) ............................................................................................................ 1
35 2071197 Seal (LH) ............................................................................................................ 1
36 1597467 Cover (Radiator) ................................................................................................ 1
36 e 1600559 Cover (Radiator Box Car Special) ...................................................................... 1
36 f 1658244 Cover (Radiator Box Car Special) ...................................................................... 1
36 1598092 Cover ............................................................................................................. 1
36 e 1600513 Cover .............................................................................................................. 1
36 f 1658243 Cover .............................................................................................................. 1
37 1544937 Seal (LH) ........................................................................................................ 1
37 1544936 Seal (RH) ....................................................................................................... 1
38 2085604 Spacer ................................................................................................................ 2
39 1624917 Knob ................................................................................................................... 1
39 2078312 Knob .............................................................................................................. 2

©2011 HYSTER COMPANY See Service Manual 1-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FLOORPLATES AND COVERS

(S/N G004V03202F → INC. 03150, 03157, 03175-03176, 03180-03184, 03189)

ITEM PART NO. DESCRIPTION QTY

40 2085894 Strap .............................................................................................................. 2
41 2021395 Cap ..................................................................................................................... 2
42 1347045 Fastener ............................................................................................................. 4
43 1531558 Insert .................................................................................................................. 6
44 2056823 Tail Light Base (RH) ........................................................................................... 1
45 1586495 Capscrew ........................................................................................................... 4
46 1540643 Capscrew ........................................................................................................... 3
47 2069203 Cover .................................................................................................................. 1
48 2056822 Tail Light Base (LH) ............................................................................................ 1
49 d 1393879 Nut ...................................................................................................................... 6

FOOTNOTES:
a Electronic Hydraulics d Not Illustrated
b Gasoline Trucks Only e → 9/2007
c Manual Controls f 9/2007 →

1-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

COWL MOUNT (FIGURE 1-5)

ITEM PART NO. DESCRIPTION QTY

1 1583611 Capscrew ............................................................................................................ 2
2 b 1586815 Cowl .................................................................................................................... 1
2 ad 1686711 Cowl .................................................................................................................... 1
2 c 1699988 Cowl .................................................................................................................... 1
3 1530243 Insert ................................................................................................................... 2
4 1640776 Insert ................................................................................................................... 7
4 1581567 Nut (Optional) ..................................................................................................... 7
4 320160 Washer (Optional) ............................................................................................... 7

©2011 HYSTER COMPANY See Service Manual 1-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ITEM PART NO. DESCRIPTION QTY

5 1605990 Capscrew ............................................................................................................ 7

FOOTNOTES:
a → PENDING PER ECN 105854 c PENDING PER ECN 105854 →
b → S/N G004V03641F d S/N G004V03642F →

1-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 1-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

COUNTERWEIGHT (FIGURE 1-6)

1-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

COUNTERWEIGHT
ITEM PART NO. DESCRIPTION QTY
1 1571797 Seal .................................................................................................................... 2
2 1595168 Seal .................................................................................................................... 1
3 1595170 Seal-Bulk ........................................................................................................... 1
4 1595169 Seal .................................................................................................................... 1
5 df 1544373 Counterweight (S80FT) ...................................................................................... 1
5 hj 1668688 Counterweight (S80FT) ...................................................................................... 1
5 df 1544375 Counterweight (S100FT) .................................................................................... 1
5 hj 1668689 Counterweight (S100FT) .................................................................................... 1
5 df 1544377 Counterweight (S120FT) .................................................................................... 1
5 hj 1668690 Counterweight (S120FT) .................................................................................. 1
5 ce 1544374 Counterweight (S80BCS) ................................................................................... 1
5 gi 1668691 Counterweight (S80BCS) ................................................................................... 1
5 ce 1544376 Counterweight (S100BCS) ................................................................................. 1
5 gi 1668692 Counterweight (S100BCS) ................................................................................. 1
5 ce 1544378 Counterweight (S120FTS) .................................................................................. 1
5 gi 1668693 Counterweight (S120FTS) .................................................................................. 1
5 ce 1544379 Counterweight (S120PRS) ................................................................................. 1
5 gi 1668694 Counterweight (S120PRS) ................................................................................. 1
6 292691 Washer ............................................................................................................... 1
7 a 292631 Capscrew ............................................................................................................ 1
7 292629 Capscrew ........................................................................................................... 1
8 1571610 Washer ............................................................................................................... 1
9 bdf 1573776 Tow Pin ............................................................................................................... 1
9 bhj 1668335 Tow Pin .............................................................................................................. 1
10 302491 Roll Pin ............................................................................................................... 1

FOOTNOTES:
a BCS and PRS Only f → S/N G004V03216F LPG TANK BRACKET
b Tow Pins are not required for Box Car or Paper Roll TYPE: SWING OUT
Specials g S/N G004V03036E → LPG TANK BRACKET
c → S/N G004V03035E LPG TANK BRACKET TYPE: SWING OUT/DROP DOWN (BOX CAR
TYPE: SWING OUT/DROP DOWN (BOX CAR SPECIAL)
SPECIAL) h S/N G004V03039E → LPG TANK BRACKET
d → S/N G004V03038E LPG TANK BRACKET TYPE: SWING OUT/DROP DOWN
TYPE: SWING OUT/DROP DOWN i S/N G004V03118E → LPG TANK BRACKET
e → S/N G004V03117E LPG TANK BRACKET TYPE: SWING OUT (BOX CAR SPECIAL)
TYPE: SWING OUT (BOX CAR SPECIAL) j S/N G004V03217F → LPG TANK BRACKET
TYPE: SWING OUT

©2011 HYSTER COMPANY See Service Manual 1-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

OVERHEAD GUARD (FIGURE 1-7)

1-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

OVERHEAD GUARD
ITEM PART NO. DESCRIPTION QTY
1 1599205 Overhead Guard (Tall 86 in.) ............................................................................ 1
1 1599211 Overhead Guard (Short 83 in.) ........................................................................... 1
2 1560671 Grommet ............................................................................................................ 1
3 1531558 Insert .................................................................................................................. 2
4 1586495 Capscrew ........................................................................................................... 2
5 2070223 Handle Assembly ................................................................................................ 1
6 2069454 Handle ............................................................................................................ 1
7 1566726 Push Button Switch ........................................................................................ 1
8 1493465 Connector ..................................................................................................... 1
9 1330414 Connector (Secondary Lock) .............................................................................. 1
10 1330437 Terminal (Pin) .................................................................................................... 2
11 1566853 Capscrew ........................................................................................................... 8
12 1528888 Nut (Shoulder) ................................................................................................... 2
13 1531557 Insert .................................................................................................................. 4
14 1536813 Handle (Grab) .................................................................................................... 1
15 1583611 Capscrew ........................................................................................................... 2
16 1558219 Grommet ............................................................................................................ 2
a 1527395 Grommet ............................................................................................................. 1
a 1494888 Plug .................................................................................................................... 2
a 1599415 Plug .................................................................................................................... 1

FOOTNOTES:
a Not Illustrated

©2011 HYSTER COMPANY See Service Manual 1-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NON-SUSPENSION SEAT (FIGURE 1-8)

(→ S/N G004V04679H INC. 04683)

1-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NON-SUSPENSION SEAT
(→ S/N G004V04679H INC. 04683)

ITEM PART NO. DESCRIPTION QTY

b 1593433 Seat-Non Suspension (Vinyl) .............................................................................. 1
e 2102122 Seat-Non Suspension Assembly (Vinyl) ............................................................. 1
g 2103360 Seat-Non Suspension (Vinyl) .............................................................................. 1
c 1593434 Seat-Non Suspension (Cloth) ............................................................................. 1
f 2102125 Seat-Non Suspension (Cloth) ............................................................................. 1
g 2103361 Seat-Non Suspension (Cloth) ............................................................................. 1
1 1563351 Kit-Seat Cushion (Vinyl) .............................................................................. 1
1 1563222 Kit-Seat Cushion (Cloth) ................................................................................. 1
1 ad 1563215 Sensor (Operator Presence) .......................................................................... 1
1 ag 1709876 Sensor (Operator Presence) ........................................................................ 1
1 a 4002682 Bracket (Operator Presence Sensor) ......................................................... 1
2 1563217 Hip Restraint (RH) ........................................................................................ 1
2 1563216 Hip Restraint (LH) ......................................................................................... 1
3 1598504 Kit-Seat Belt (Black) ....................................................................................... 1
3 1636120 Kit-Red Seat Belt ............................................................................................ 1
4 1591652 Wire Harness .................................................................................................. 1
5 b 1459173 Kit-Seat Rail ................................................................................................... 1
5 h 1690996 Kit-Seat Rail (Alternate Part) ....................................................................... 1
6 b 191941 Nut ...................................................................................................................... 4
6 h 302400 Nut (Alternate Part) ........................................................................................... 4
ah 1677286 Stud (Alternate Part) ......................................................................................... 4
a 335988 Information Case ................................................................................................ 1
a 335991 Cover (Information Case) ................................................................................... 1

FOOTNOTES:
a Not Illustrated e S/N G004V03442F ↔ S/N G004V04306G
b → S/N G004V03441F f S/N G004V03697G ↔ S/N G004V04306G
c → S/N G004V03696G g S/N G004V04307G →
d → S/N G004V04306G h S/N G004V03442F →

©2011 HYSTER COMPANY See Service Manual 1-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NON SUSPENSION SEAT (FIGURE 1-9)

WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683)

1-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NON SUSPENSION SEAT

WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683)

ITEM PART NO. DESCRIPTION QTY

4603376 Seat-Non Suspension ....................................................................................... 1
1 1563351 Kit-Seat Cushion (Vinyl) .............................................................................. 1
2 1563216 Hip Restraint (LH) ......................................................................................... 1
3 1690996 Kit-Seat Rail .................................................................................................. 1
4 1709876 Sensor (Operator Presence) ........................................................................ 1
5 4002682 Bracket (Operator Presence Sensor) ......................................................... 1
6 4013095 Wire Harness ................................................................................................ 1
7 1563217 Hip Restraint (RH) ........................................................................................ 1
8 1584060 Storage Box .................................................................................................. 1
9 1482950 Cover ............................................................................................................. 1
10 1603701 Seat Belt ............................................................................................................ 1
10 1598504 Kit-Seat Belt (Black) ............................................................................................ 1
10 1636120 Kit-Red Seat Belt ................................................................................................ 1
11 313828 Nut ...................................................................................................................... 4
12 1677286 Stud .................................................................................................................... 4
13 221536 Capscrew ........................................................................................................... 2
14 1581852 Washer ............................................................................................................... 6
15 221353 Locknut .............................................................................................................. 2
16 2107969 Cover (Seat Side Electrical) ............................................................................. 1
17 4007891 Cover Plate ........................................................................................................ 1
18 296357 Washer ............................................................................................................... 2
19 1694830 Capscrew ........................................................................................................... 2
20 292500 Capscrew ........................................................................................................... 2
21 15127 Washer ............................................................................................................... 1
22 272133 Clamp ................................................................................................................. 1
23 1593334 Nut ...................................................................................................................... 2

©2011 HYSTER COMPANY See Service Manual 1-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

SEMI-SUSPENSION SEAT (FIGURE 1-10)

WITH AND WITHOUT ELECTRONIC CONTROLS (→ 7/2006)

1-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

SEMI-SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (→ 7/2006)
KEY:
A: Without Arm Controls
B: With Arm Controls
QTY
ITEM PART NO. DESCRIPTION A B
1 b 1593435 Seat-Semi Suspension (Vinyl) (Vinyl) ........................................................ 1 ..
1 c 2102126 Seat-Semi Suspension (Vinyl) (Alternate Part) .......................................... 1 ..
1 b 1593436 Seat-Semi Suspension (Cloth) (Cloth) ....................................................... 1 ..
1 c 2102127 Seat-Semi Suspension (Cloth) (Alternate Part) ......................................... 1 ..
1 1593427 Seat-Semi Suspension (Vinyl) (Vinyl) ........................................................ .. 1
1 1593428 Seat-Semi Suspension (Cloth) (Cloth) ....................................................... .. 1
2 1362058 Information Case ................................................................................... 1 1
3 1382111 Seat Cushion (Back Cushion) (Vinyl) .................................................... 1 1
3 1382113 Seat Cushion (Back Cushion) (Cloth) .................................................... 1 1
4 1563224 Hip Restraint (LH) .................................................................................. 1 1
4 1563225 Hip Restraint (RH) ................................................................................. 1 ..
5 1598504 Kit-Seat Belt (Black) ............................................................................... 1 1
5 1636120 Kit-Red Seat Belt ................................................................................... 1 1
6 1382112 Seat Cushion (Vinyl) .............................................................................. 1 1
6 1382114 Seat Cushion (Cloth) ............................................................................. 1 1
7 1483023 Guide ..................................................................................................... 1 1
8 1563227 Knob ...................................................................................................... 1 1
9 b 1459173 Kit-Seat Rail ........................................................................................... 1 1
9 c 1690995 Kit-Seat Rail (Alternate Part) ................................................................. 1 1
10 2075428 Wire Harness (With Electronic Controls) ............................................... .. 1
10 1591652 Wire Harness (With Hip Restraints) ....................................................... 1 ..
a 1563211 Knob (Electronic Control Arm) ............................................................... .. 1
a 1362049 Kit-Shock Absorber ................................................................................ 1 1
a 1563215 Sensor (Operator Presence) .................................................................. 1 1
a 1563210 Cap (Electronic Control Arm) ................................................................. .. 1
11 b 191941 Nut .............................................................................................................. 4 4
11 c 302400 Nut (Alternate Part) .................................................................................... 4 4
ac 1677286 Stud (Alternate Part) .................................................................................. 4 4

FOOTNOTES:
a Not Illustrated c PENDING PER ECN 105255 →
b → PENDING PER ECN 105255

©2011 HYSTER COMPANY See Service Manual 1-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

SEMI-SUSPENSION SEAT (FIGURE 1-11)

WITH AND WITHOUT ELECTRONIC CONTROLS (7/2006 ↔ S/N G004V04679H)

1-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

SEMI-SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (7/2006 ↔ S/N G004V04679H)
KEY:
A: With Hip Restraints
B: With Electronic Control Arm
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
d 1593435 Seat-Semi Suspension (Vinyl) ................................................................... 1 ..
h 2102126 Seat-Semi Suspension (Vinyl) ................................................................... 1 ..
j 2103364 Seat-Semi Suspension (Vinyl) ................................................................... 1 ..
d 1593436 Seat-Semi Suspension (Cloth) ................................................................... 1 ..
h 2102127 Seat-Semi Suspension (Cloth) ................................................................... 1 ..
k 2103365 Seat-Semi Suspension (Cloth) ................................................................... 1 ..
c 2085193 Seat-Semi Suspension (Vinyl) ................................................................... .. 1
g 2102128 Seat-Semi Suspension (Vinyl) ................................................................... .. 1
k 2103366 Seat-Semi Suspension (Vinyl) ................................................................... .. 1
e 2085194 Seat-Semi Suspension (Cloth) (Cloth) ....................................................... .. 1
i 2102129 Seat-Semi Suspension (Cloth) ................................................................... .. 1
k 2103367 Seat-Semi Suspension (Cloth) ................................................................... .. 1
1 1382111 Seat Cushion (Back Cushion) (Vinyl) .................................................... 1 1
1 1382113 Seat Cushion (Back Cushion) (Cloth) .................................................... 1 1
2 1563224 Hip Restraint (LH) .................................................................................. 1 1
2 1563225 Hip Restraint (RH) ................................................................................. 1 ..
3 1598504 Kit-Seat Belt (Black) ............................................................................... 1 1
3 1636120 Kit-Red Seat Belt ................................................................................... 1 1
4 1382112 Seat Cushion (Vinyl) .............................................................................. 1 1
4 1382114 Seat Cushion (Cloth) ............................................................................. 1 1
4 f 1563215 Sensor (Operator Presence) .................................................................. 1 1
4 k 1709876 Sensor (Operator Presence) ............................................................... 1 1
a 4002682 Bracket (Operator Presence Sensor) ................................................. 1 1
5 b 1483023 Guide ..................................................................................................... 1 1
6 1563227 Knob ...................................................................................................... 1 1
7 c 1459173 Kit-Seat Rail ........................................................................................... 1 1
7 l 1690995 Kit-Seat Rail ........................................................................................... 1 1
8 1591652 Wire Harness ......................................................................................... 1 ..
8 1654891 Wire Harness ......................................................................................... .. 1
9 1362058 Information Case ................................................................................... 1 1
10 1374190 Cover (Information Case) ........................................................................... 1 1
11 1537551 Nut ............................................................................................................. 1 1
12 1500901 Clip ............................................................................................................. 1 1
13 296149 Capscrew ................................................................................................... 1 1
14 1500912 Clip ............................................................................................................ 1 1
15 c 191941 Nut .............................................................................................................. 4 4
15 l 302400 Nut (Alternate Part) .................................................................................. 4 4
al 1677286 Stud (Alternate Part) ................................................................................ 4 4
a 1362049 Kit-Shock Absorber ................................................................................ 1 1
a 1647532 Foam ...................................................................................................... .. 1
a 1563211 Knob (Electronic Control Arm) ............................................................... .. 1

©2011 HYSTER COMPANY See Service Manual 1-29

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a Not Illustrated g S/N G004V03606F ↔ S/N G004V04306G
b Not used on 2102126 h S/N G004V03626F ↔ S/N G004V04306G
c → S/N G004V03605F i S/N G004V03642F ↔ S/N G004V04306G
d → S/N G004V03625F j S/N G004V04306G →
e → S/N G004V03641F k S/N G004V04307G →
f → S/N G004V04306G l S/N G004V03606F →

1-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 1-31

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

SEMI-SUSPENSION SEAT (FIGURE 1-12)

WITH AND WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683)

1-32 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

SEMI-SUSPENSION SEAT
WITH AND WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683)
KEY:
A: With Hip Restraints
B: With Electronic Control Arm
QTY
ITEM PART NO. DESCRIPTION A B
4601836 Seat-Semi Suspension (Vinyl) ................................................................... 1 ..
4601837 Seat-Semi Suspension (Cloth) ................................................................... 1 ..
4005807 Seat-Semi Suspension (Vinyl) ................................................................... .. 1
4005808 Seat-Semi Suspension (Cloth) ................................................................... .. 1
1 1382111 Seat Cushion (Back Cushion) (Vinyl) .................................................... 1 1
1 1382113 Seat Cushion (Back Cushion) (Cloth) .................................................... 1 1
2 1563224 Hip Restraint (LH) .................................................................................. 1 ..
3 1382112 Seat Cushion (Vinyl) .............................................................................. 1 1
3 1382114 Seat Cushion (Cloth) ............................................................................. 1 1
4 1563227 Knob ...................................................................................................... 1 1
5 1690995 Kit-Seat Rail ........................................................................................... 1 1
6 1709876 Sensor (Operator Presence) .................................................................. 1 1
7 4002682 Bracket (Operator Presence Sensor) .................................................... 1 1
8 4013095 Wire Harness ......................................................................................... 1 1
9 1563225 Hip Restraint (RH) ................................................................................. 1 ..
9 4005010 Armrest (Slider with Mini Lever) (FFigure 1-17)................................... .. 1
10 1362058 Information Case ................................................................................... 1 1
11 19901 Roll Pin ....................................................................................................... 1 1
12 1603701 Seat Belt ..................................................................................................... 1 1
12 1598504 Kit-Seat Belt (Black) ................................................................................... 1 1
12 1636120 Kit-Red Seat Belt ........................................................................................ 1 1
13 1581852 Washer ....................................................................................................... 4 4
14 221533 Capscrew ................................................................................................... 2 2
15 2107969 Cover (Seat Side Electrical) ....................................................................... 1 1
16 4008420 Cover Plate ................................................................................................ 1 ..
17 296357 Washer ....................................................................................................... 2 2
18 1694830 Capscrew ................................................................................................... 2 2
19 1677286 Stud ............................................................................................................ 4 4
20 313828 Nut .............................................................................................................. 4 4
a 221530 Capscrew ................................................................................................... .. 1
a 221353 Locknut ....................................................................................................... .. 1
a 1362049 Kit-Shock Absorber .................................................................................... 1 1

FOOTNOTES:
a Not Illustrated

©2011 HYSTER COMPANY See Service Manual 1-33

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FULL SUSPENSION SEAT (FIGURE 1-13)

WITH AND WITHOUT ELECTRONIC CONTROLS — WITH LIMITED BACK TILT
(→ S/N G004V04679H INC. 04683)

1-34 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FULL SUSPENSION SEAT

WITH AND WITHOUT ELECTRONIC CONTROLS – WITH LIMITED BACK TILT
(→ S/N G004V04679H INC. 04683)
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
1612103 Seat-Full Suspension (With Limited Back Angle) (Vinyl) .......... 1 .. .. ..
1612104 Seat-Full Suspension (With Limited Back Angle) (Cloth) ......... .. 1 .. ..
b 2089675 Seat-Full Suspension (With Limited Back Angle) (Vinyl) .......... .. .. 1 ..
b 2089676 Seat-Full Suspension (With Limited Back Angle) (Cloth) ......... .. .. .. 1
c 2086107 Seat-Full Suspension (With Limited Back Angle) (Vinyl) .......... .. .. 1 ..
c 2086108 Seat-Full Suspension (With Limited Back Angle) (Cloth) ......... .. .. .. 1
1 1470152 Seat Cushion (Back Cushion) (Vinyl) ................................... 1 .. 1 ..
1 1470153 Seat Cushion (Back Cushion) (Cloth) ................................... .. 1 .. 1
2 1470157 Hip Restraint (LH) ................................................................. 1 1 1 1
2 1470156 Hip Restraint (RH) ................................................................ 1 1 .. ..
3 1598504 Kit-Seat Belt (Black) ............................................................. 1 1 1 1
3 1636120 Kit-Red Seat Belt .................................................................. 1 1 1 1
4 1563207 Seat Cushion (Vinyl) ............................................................. 1 .. 1 ..
4 1566453 Seat Cushion (Cloth) ............................................................ .. 1 .. 1
5 1470163 Kit-Weight Adjuster ............................................................... 1 1 1 1
5 1584631 Knob ................................................................................. 1 1 1 1
5 1600126 Handle .............................................................................. 1 1 1 1
6 1470161 Kit-Seat Rail .......................................................................... 1 1 1 1
7 1591652 Wire Harness ........................................................................ 1 1 .. ..
7 1654891 Wire Harness ........................................................................ .. .. 1 1
a 1483828 Kit-Gas Spring (Mounted to the rear of the seat) ................. 1 1 1 1
a 1563210 Cap (Electronic Control Arm) ................................................ .. .. 1 1
a 1563211 Knob (Electronic Control Arm) .............................................. .. .. 1 1
a 1470155 Information Case (Kit) ........................................................... 1 1 1 1
a 1467529 Kit-Spring .............................................................................. 1 1 1 1
a 1627639 Weight Adjust Rack .............................................................. 1 1 1 1
a 1467525 Kit-Bumper ............................................................................ 1 1 1 1
a 1467523 Kit-Boot ................................................................................. 1 1 1 1
a 1467526 Kit-Shaft and Bearing ........................................................... 1 1 1 1
a 1467524 Kit-Bearing ............................................................................ 1 1 1 1
a 1467527 Kit-Weight Adjuster Indicator ................................................ 1 1 1 1
a 1563208 Sensor (Operator Presence) ................................................ 1 1 1 1
8 191941 Nut ............................................................................................ 4 4 4 4
9 1500901 Clip ............................................................................................ .. .. 1 1
10 1500912 Clip ............................................................................................ .. .. 1 1
11 1537551 Nut ............................................................................................ .. .. 1 1
12 296149 Capscrew .................................................................................. .. .. 1 1

FOOTNOTES:
a Not Illustrated c With Non-Flip Up E-Control Armrest
b With Flip Up E-Control Armrest

©2011 HYSTER COMPANY See Service Manual 1-35

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FULL SUSPENSION SWIVEL SEAT (FIGURE 1-14)

WITH AND WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683)

1-36 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FULL SUSPENSION SWIVEL SEAT

WITH AND WITHOUT ELECTRONIC CONTROLS (S/N G004V04680H → EXC. 04683)
KEY:
A: With Hip Restraints
B: With Electronic Controls
QTY
ITEM PART NO. DESCRIPTION A B
2086298 Seat-Full Suspension (Vinyl) ...................................................................... 1 ..
2086299 Seat-Full Suspension (Cloth) ..................................................................... 1 ..
2086300 Seat-Full Suspension (Vinyl) ...................................................................... .. 1
2086301 Seat-Full Suspension (Cloth) ..................................................................... .. 1
1 1470153 Seat Cushion (Back Cushion) (Cloth) .................................................... 1 ..
1 1470152 Seat Cushion (Back Cushion) (Vinyl) .................................................... .. 1
2 1566453 Seat Cushion (Cloth) ............................................................................. 1 ..
2 1563207 Seat Cushion (Vinyl) .............................................................................. .. 1
2 1563208 Sensor (Operator Presence) .................................................................. 1 1
3 1591652 Wire Harness ......................................................................................... 1 ..
3 1654891 Wire Harness ......................................................................................... .. 1
4 1470157 Hip Restraint (LH) .................................................................................. 1 1
4 1470156 Hip Restraint (RH) ................................................................................. 1 ..
5 1470161 Kit-Seat Rail ........................................................................................... 1 1
6 1470163 Kit-Weight Adjuster ................................................................................ 1 1
6 1584631 Knob .................................................................................................. 1 1
6 1600126 Handle ............................................................................................... 1 1
7 1598504 Kit-Seat Belt (Black) ............................................................................... 1 1
7 1636120 Kit-Red Seat Belt ................................................................................... 1 1
a 1684395 Kit-Swivel Seat Full Susp ....................................................................... 1 1
a 1467523 Kit-Boot .............................................................................................. 1 1
a 1467527 Kit-Weight Adjuster Indicator ............................................................. 1 1
a 1470160 Scissor ............................................................................................... 1 1
a 1467529 Kit-Spring ........................................................................................... 1 1
a 1627639 Weight Adjust Rack ....................................................................... 1 1
a 1467526 Kit-Shaft and Bearing ............................................................................. 1 1
a 1467524 Kit-Bearing ............................................................................................. 1 1
a 1467525 Kit-Bumper ............................................................................................. 1 1
a 1470155 Information Case (Kit) ............................................................................ 1 ..
8 191941 Nut .............................................................................................................. 4 4

FOOTNOTES:
a Not Illustrated

©2011 HYSTER COMPANY See Service Manual 1-37

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FULL SUSPENSION SEAT (FIGURE 1-15)

MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON-SWIVEL (S/N G004V04680H → EXC. 04683)

1-38 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FULL SUSPENSION SEAT

MANUAL AND ELECTRO-HYDRAULIC – SWIVEL AND NON-SWIVEL (S/N G004V04680H → EXC. 04683)
KEY:
A: w/o Electronic Control Arm
B: w/ Electronic Control Arm
QTY
ITEM PART NO. DESCRIPTION A B
4603382 Seat-Full Suspension (Vinyl) (Non-Swivel) ................................................ 1 1
4603383 Seat-Full Suspension (Cloth) (Non-Swivel) ................................................ 1 1
4603384 Seat-Full Suspension (Vinyl) (Swivel) ........................................................ 1 1
4603385 Seat-Full Suspension (Cloth) (Swivel) ....................................................... 1 1
1 1703900 Kit-Cushion (Seat and Back, Cloth) ....................................................... 1 1
1 1703903 Kit-Cushion (Seat and Back, Vinyl) ........................................................ 1 1
2 1703901 Kit-Cushion (Back Cushion, Vinyl) .................................................... 1 1
2 1703898 Kit-Cushion (Back Cushion, Cloth) .................................................... 1 1
2 ..... Back Cushion ................................................................................ 1 1
2 ..... Screw ............................................................................................ 2 2
3 1703902 Kit-Seat Cushion (Vinyl) .................................................................... 1 1
3 1703899 Kit-Seat Cushion (Cloth) .................................................................... 1 1
3 ..... Seat Cushion ................................................................................. 1 1
3 ..... Spring ............................................................................................ 2 2
3 ..... Cotter Pin ...................................................................................... 2 2
4 1703892 Kit-Weight Adjuster ................................................................................ 1 1
4 ..... Knob .................................................................................................. 1 1
4 ..... Bushing ............................................................................................. 1 1
4 ..... Washer .............................................................................................. 1 1
4 ..... Pin ..................................................................................................... 1 1
5 1703893 Kit-Service (Front Panel) (Non Swivel) .................................................. 1 1
5 ..... Front Panel ........................................................................................ 1 1
5 ..... Socket Head Capscrew ..................................................................... 2 2
5 ..... Roll Pin .............................................................................................. 1 1
5 1703894 Kit-Service (Front Panel) (With Swivel) ................................................. 1 1
5 ..... Front Panel ........................................................................................ 1 1
5 ..... Knob .................................................................................................. 1 1
5 ..... Socket Head Capscrew ..................................................................... 1 1
5 ..... Roll Pin .............................................................................................. 2 2
6 1703904 Kit-Seat Rail ........................................................................................... 1 1
6 ..... Locking Rail ....................................................................................... 1 1
6 ..... Slave Rail .......................................................................................... 1 1
6 ..... Bolt .................................................................................................... 4 4
6 ..... Nut ..................................................................................................... 4 4
7 4013095 Wire Harness ......................................................................................... 1 1
7 1563208 Sensor (Operator Presence) .................................................................. 1 1
8 4009620 Armrest (Left-Hand Side) ........................................................................... 1 1
8 4612911 Armrest (Left-Hand Side) (Alternate Part) .................................................. 1 1
9 18735 Screw ......................................................................................................... 2 1
9 18738 Capscrew ................................................................................................... .. 1
10 1512536 Washer ....................................................................................................... 2 1
10 4007319 Spacer ........................................................................................................ .. 1
11 221353 Locknut ....................................................................................................... 2 2
12 1581852 Washer ....................................................................................................... 6 6
13 221536 Capscrew ................................................................................................... 2 1

©2011 HYSTER COMPANY See Service Manual 1-39

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FULL SUSPENSION SEAT

MANUAL AND ELECTRO-HYDRAULIC – SWIVEL AND NON-SWIVEL (S/N G004V04680H → EXC. 04683)
KEY:
A: w/o Electronic Control Arm
B: w/ Electronic Control Arm
QTY
ITEM PART NO. DESCRIPTION A B
14 4004776 Cover Plate ................................................................................................ 1 1
15 19901 Roll Pin ....................................................................................................... 1 1
16 1598504 Kit-Seat Belt (Black) ................................................................................... 1 1
16 1636120 Kit-Red Seat Belt ........................................................................................ 1 1
17 2099951 Armrest (Right-Hand Side) ......................................................................... 1 ..
17 ..... Armrest (Electro-Hydraulic) ........................................................................ .. 1
17 4005010 Armrest (Slider with Mini Lever) (FFigure 1-18)................................... .. 1
17 ..... Mini-Lever Modules (FFigure 4-19, FFigure 4-17, FFigure 4-18)....... .. 1
18 4007318 Spacer ........................................................................................................ 2 2
19 169874 Nut .............................................................................................................. 4 4
20 18462 Capscrew ................................................................................................... 2 2
21 18471 Capscrew ................................................................................................... 2 2
22 1694830 Capscrew ................................................................................................... 2 2
23 296357 Washer ....................................................................................................... 2 2
24 2107969 Cover (Seat Side Electrical) ....................................................................... 1 1
25 313828 Nut .............................................................................................................. 4 4
26 1677286 Stud ............................................................................................................ 4 4
27 1694700 Spacer ........................................................................................................ .. 1
28 221542 Capscrew ................................................................................................... .. 1
a 1470155 Information Case (Kit) ................................................................................ 1 1
a 4601500 Wire Harness (Seat Adapter) (FFigure 4-32)............................................ 1 1
a 4027341 Bracket (Angle Controller) .......................................................................... 1 1
1703895 Kit-Service Internal Tether-80 MM Travel .................................................. 1 1
1703896 Kit-Service Internal Tether-56 MM Travel .................................................. 1 1
1703897 Kit-Service Internal Tether-40 MM Travel .................................................. 1 1

FOOTNOTES:
a Not Illustrated

1-40 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 1-41

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FULL SUSPENSION SEAT (FIGURE 1-16)

SHEET 2 OF 2 (S/N G004V04680H → EXC. 04683)

1-42 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FULL SUSPENSION SEAT

SHEET 2 OF 2 (S/N G004V04680H → EXC. 04683)

ITEM PART NO. DESCRIPTION QTY

1 1703891 Kit-Recliner (Back Seat Adjustment) .................................................................. 1
2 ..... Knob ............................................................................................................... 1
3 ..... Lever .............................................................................................................. 1
4 1482905 Plate ............................................................................................................... 1
5 ..... Spring ............................................................................................................. 1
6 1482906 Latch ............................................................................................................... 1
7 1367150 Nut .................................................................................................................. 2
8 1703890 Kit-Damper Service ............................................................................................. 1
9 1584632 Damper ........................................................................................................... 1
10 1367150 Nut .................................................................................................................. 2
11 1584638 Bolt ................................................................................................................. 2

©2011 HYSTER COMPANY See Service Manual 1-43

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ARMREST ASSEMBLY (FIGURE 1-17)

MINI-LEVER MODULES — SEMI-SUSPENSION SEAT WITH HIP RESTRAINTS

1-44 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ARMREST ASSEMBLY
MINI-LEVER MODULES – SEMI-SUSPENSION SEAT WITH HIP RESTRAINTS

ITEM PART NO. DESCRIPTION QTY

4005010 Armrest (Slider with Mini Lever) .......................................................................... 1
1 ..... Slider Assembly .............................................................................................. 1
2 1661511 Armrest (Slider) .......................................................................................... 1
3 1655865 Handle (Slider) ........................................................................................... 1
4 227157 Screw ......................................................................................................... 2
5 4007052 Bracket Wldmt ................................................................................................ 1
6 296360 Washer ........................................................................................................... 4
7 313828 Nut .................................................................................................................. 4
8 1531558 Insert .............................................................................................................. 3
9 296165 Capscrew ....................................................................................................... 2
10 ..... Slider Assembly .............................................................................................. 1
11 1661511 Armrest (Slider) .......................................................................................... 1
12 1655865 Handle (Slider) ........................................................................................... 1
13 227157 Screw ......................................................................................................... 2
14 4004775 Bracket ................................................................................................................ 1
15 4603493 Cover .................................................................................................................. 1
16 2062875 Capscrew ............................................................................................................ 5
17 316826 Nut ...................................................................................................................... 1
18 320160 Washer ............................................................................................................... 1
19 1650640 Washer ............................................................................................................... 2
20 313828 Nut ...................................................................................................................... 2
21 296360 Washer ............................................................................................................... 2
22 292500 Capscrew ............................................................................................................ 2
23 4005805 Cover Plate ......................................................................................................... 1
24 1593334 Nut ...................................................................................................................... 2
25 4603492 Cover .................................................................................................................. 1

©2011 HYSTER COMPANY See Service Manual 1-45

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ARMREST ASSEMBLY (FIGURE 1-18)

MINI-LEVER MODULES

1-46 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ARMREST ASSEMBLY
MINI-LEVER MODULES

ITEM PART NO. DESCRIPTION QTY

4005010 Armrest (Slider with Mini Lever) .......................................................................... 1
1 ..... Slider Assembly .............................................................................................. 1
2 1661511 Armrest (Slider) .......................................................................................... 1
3 1655865 Handle (Slider) ........................................................................................... 1
4 227157 Screw ......................................................................................................... 2
5 4007052 Bracket Wldmt ................................................................................................ 1
6 296360 Washer ........................................................................................................... 4
7 313828 Nut .................................................................................................................. 4
8 1531558 Insert .............................................................................................................. 3
9 296165 Capscrew ....................................................................................................... 2
10 ..... Slider Assembly .............................................................................................. 1
11 1661511 Armrest (Slider) .......................................................................................... 1
12 1655865 Handle (Slider) ........................................................................................... 1
13 227157 Screw ......................................................................................................... 2
14 4004775 Bracket ................................................................................................................ 1
15 316826 Nut ...................................................................................................................... 1
16 320160 Washer ............................................................................................................... 1
17 1650640 Washer ............................................................................................................... 2
18 4007319 Spacer ................................................................................................................ 1
19 18738 Capscrew ............................................................................................................ 1
20 296360 Washer ............................................................................................................... 2
21 313828 Nut ...................................................................................................................... 2
22 18462 Capscrew ............................................................................................................ 1
23 18471 Capscrew ............................................................................................................ 1
24 4007318 Spacer ................................................................................................................ 1
25 4004776 Cover Plate ......................................................................................................... 1
26 169874 Nut ...................................................................................................................... 2
27 4603492 Cover .................................................................................................................. 1
28 2062875 Capscrew ............................................................................................................ 5
29 4603493 Cover .................................................................................................................. 1

©2011 HYSTER COMPANY See Service Manual 1-47

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FORK (FIGURE 1-19)

STANDARD TAPER HOOK TYPE — CLASS III

KEY:
A: 125 mm (5 in.) x 50 mm (2 in.)
B: 150 mm (6 in.) x 50 mm (2 in.)
QTY
ITEM PART NO. DESCRIPTION A B
1 367420 Fork (42 in.) ................................................................................................ 2 ..
1 367421 Fork (48 in.) ................................................................................................ 2 ..
1 367422 Fork (54 in.) ................................................................................................ 2 ..
1 367423 Fork (60 in.) ................................................................................................ 2 ..
1 1399916 Fork (60 in.) ................................................................................................ .. 2
1 367424 Fork (72 in.) ................................................................................................ 2 ..
1 1399917 Fork (72 in.) ................................................................................................ .. 2
2 1523734 Pin .............................................................................................................. 1 1
3 1523732 Knob ........................................................................................................... 1 1
4 1477166 Washer ....................................................................................................... 1 1
5 1500784 Spring ......................................................................................................... 1 1
6 1523737 Pin .............................................................................................................. 1 1
7 1477237 Wedge Band .............................................................................................. 1 1
1523739 Kit-Latch (Includes Items 2-7) .................................................................... 1 1

1-48 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FORK (FIGURE 1-20)

STANDARD TAPER HOOK TYPE — CLASS IV

KEY:
A: 150 mm (6 in.) x 50 mm (2 in.)
B: 150 mm (6 in.) x 60 mm (2.4 in.)
QTY
ITEM PART NO. DESCRIPTION A B
1 1458264 Fork (42 in.) ................................................................................................ .. 2
1 1333001 Fork (48 in.) ................................................................................................ .. 2
1 1399920 Fork (48 in.) ................................................................................................ 2 ..
1 1333002 Fork (54 in.) ................................................................................................ .. 2
1 1399921 Fork (54 in.) ................................................................................................ 2 ..
1 1333003 Fork (60 in.) ................................................................................................ .. 2
1 1399922 Fork (60 in.) ................................................................................................ 2 ..
1 1333004 Fork (72 in.) ................................................................................................ .. 2
1 1399919 Fork (42 in.) ................................................................................................ 2 ..
2 1523734 Pin .............................................................................................................. 1 1
3 1523732 Knob ........................................................................................................... 1 1
4 1500786 Spring ......................................................................................................... 1 1
5 1523741 Pin .............................................................................................................. 1 1
1523742 Kit-Latch (Class IV) (Includes Items 2-5) ................................................... 2 2

©2011 HYSTER COMPANY See Service Manual 1-49

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FORK (FIGURE 1-21)

POLISHED WITH FULL BOTTOM TAPER HOOK TYPE

KEY:
A: Class III
B: Class IV
QTY
ITEM PART NO. DESCRIPTION A B
1 1465545 Fork (48 in.) ................................................................................................ 1 ..
1 1465547 Fork (48 in.) ................................................................................................ .. 1
1 1465546 Fork (54 in.) ................................................................................................ 1 ..
1 1465548 Fork (54 in.) ................................................................................................ .. 1
2 1523734 Pin .............................................................................................................. 1 1
3 1523732 Knob ........................................................................................................... 1 1
4 1477166 Washer ....................................................................................................... 1 ..
5 1500784 Spring ......................................................................................................... 1 ..
5 1500786 Spring ......................................................................................................... .. 1
6 1523737 Pin .............................................................................................................. 1 ..
6 1523741 Pin .............................................................................................................. .. 1
7 1477237 Wedge Band .............................................................................................. 1 ..
1523739 Kit-Latch (Includes Items 2-7) .................................................................... 1 ..
1523742 Kit-Latch (Class IV) (Includes Items 2-3, 5-6) ............................................ .. 1

1-50 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 1-51

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

LOAD BACKREST EXTENSION (FIGURE 1-22)

1-52 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

LOAD BACKREST EXTENSION

KEY:
A: Polished Forks with Full Bottom Taper
B: Standard Taper
QTY
ITEM PART NO. DESCRIPTION A B
1 1387339 Load Backrest (42 in.) (Class III) ................................................................ .. 1
1 1387340 Load Backrest (42 in.) (Class III) ................................................................ 1 ..
1 1387341 Load Backrest (48 in.) (Class III) ................................................................ .. 1
1 1387342 Load Backrest (48 in.) (Class III) ................................................................ 1 ..
1 1387347 Load Backrest (42 in.) (Class IV) ............................................................... .. 1
1 1387348 Load Backrest (48 in.) (Class IV) ............................................................... .. 1
1 1481225 Load Backrest (42 in.) (Class IV) ............................................................... 1 ..
1 1464863 Load Backrest (48 in.) (Class IV) ............................................................... 1 ..
2 1354923 Capscrew (Standard Carriage) .................................................................. 4 4
2 1387330 Capscrew (Side-Shift Carriage) ................................................................. 4 4
3 a 221771 Washer ....................................................................................................... 4 4
3 296423 Washer ....................................................................................................... 4 4
4 292683 Lockwasher ................................................................................................ 4 4
5 292656 Nut .............................................................................................................. 4 4

FOOTNOTES:
a Optional

©2011 HYSTER COMPANY See Service Manual 1-53

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC MINI LEVER LABELS (FIGURE 1-23)

AUXILIARY SINGLE FUNCTION

1-54 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC MINI LEVER LABELS

AUXILIARY SINGLE FUNCTION

ITEM PART NO. DESCRIPTION QTY

1 1581055 Label (Hoist and Tilt) ........................................................................................... 1
2 2073115 Label (Reach) ..................................................................................................... 1
3 2073114 Label (Swing) ...................................................................................................... 1
4 2073118 Label (Push/Pull) ................................................................................................ 1
5 2085877 Label (Clamp) ..................................................................................................... 1
6 2073116 Label (Load Stabilizer) ........................................................................................ 1
7 2073117 Label (Scoop) ..................................................................................................... 1
8 2073119 Label (Upender) .................................................................................................. 1
9 2073121 Label (Rotate) ..................................................................................................... 1
10 2073122 Label (Side-Shift) ................................................................................................ 1
11 2073123 Label (Fork Spread) ............................................................................................ 1
12 2085875 Label (Hoist and Tilt with Return to Set Tilt) ....................................................... 1

©2011 HYSTER COMPANY See Service Manual 1-55

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC MINI LEVER LABELS (FIGURE 1-24)

AUXILIARY DUAL FUNCTION

1-56 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC MINI LEVER LABELS

AUXILIARY DUAL FUNCTION

ITEM PART NO. DESCRIPTION QTY

1 2081229 Label (Reach/Side-Shift) ..................................................................................... 1
2 2081230 Label (Reach/Rotate) .......................................................................................... 1
3 2081231 Label (Reach/Upender) ...................................................................................... 1
4 2081232 Label (Reach/Scoop) .......................................................................................... 1
5 2081233 Label (Reach/Load Stabilizer) ............................................................................ 1
6 2081234 Label (Reach/Swing) .......................................................................................... 1
7 2081235 Label (Reach/Fork Spread) ................................................................................ 1
8 2081236 Label (Side-Shift/Push or Pull) ............................................................................ 1
9 2081237 Label (Side-Shift/Rotate) .................................................................................... 1
10 2081238 Label (Side-Shift/Upender) ................................................................................. 1
11 2081239 Label (Side-Shift/Scoop) ..................................................................................... 1
12 2081240 Label (Side-Shift/Load) ....................................................................................... 1
13 2081241 Label (Side-Shift/Swing) ..................................................................................... 1
14 2081242 Label (Side-Shift/Fork Spread) ........................................................................... 1
15 2081243 Label (Push or Pull/Load) ................................................................................... 1
16 2081244 Label (Rotate/Upender) ...................................................................................... 1
17 2081245 Label (Rotate/Scoop) .......................................................................................... 1
18 2081246 Label (Rotate/Load Stabilizer) ............................................................................ 1
19 2081247 Label (Rotate/Swing) .......................................................................................... 1
20 2081248 Label (Rotate/Fork Spreader) ............................................................................. 1
21 2081249 Label (Scoop/Load Stabilizer) ............................................................................. 1
22 2081250 Label (Load Stabilizer/Swing) ............................................................................. 1
23 2081251 Label (Load Stabilizer/Fork Spread) ................................................................... 1
24 2081252 Label (Swing/Fork Spread) ................................................................................. 1
25 1581055 Label (Hoist and Tilt) ........................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 1-57

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

CONTROL LEVER LABELS (FIGURE 1-25)

1-58 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

CONTROL LEVER LABELS

ITEM PART NO. DESCRIPTION QTY
1 2070296 Lens (Lift) .......................................................................................................... 1
2 2070297 Lens (Tilt) ........................................................................................................... 1
3 2070298 Lens (Reach) ...................................................................................................... 1
3 2070299 Lens (Swing) ....................................................................................................... 1
3 2070300 Lens (Load Stabilizer) ......................................................................................... 1
3 2070301 Lens (Scoop) ...................................................................................................... 1
3 2070302 Lens (Upender) ................................................................................................... 1
3 2070303 Lens (Push/Pull) ................................................................................................. 1
3 2070304 Lens (Clamp) ...................................................................................................... 1
3 2070305 Lens (Rotate) ...................................................................................................... 1
3 2070306 Lens (Side-Shift) ................................................................................................. 1
3 2070307 Lens (Fork Spread) ............................................................................................. 1
a 2070655 Lens (Blank) ...................................................................................................... 1

FOOTNOTES:
a Not Illustrated

©2011 HYSTER COMPANY See Service Manual 1-59

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

LABELS (FIGURE 1-26)

INTERIOR

1-60 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

LABELS
INTERIOR

ITEM PART NO. DESCRIPTION QTY

1 b. . . . . Nameplate .......................................................................................................... 1
1 170658 Rivet .................................................................................................................... 4
2 389688 Nameplate .......................................................................................................... 1
3 1385102 Label (Drive Train Protection) ............................................................................. 1
4 a 1589377 Label (Basic Powershift Transmission) ............................................................... 1
5 c 1589397 Label (DuraMatch Transmission) ........................................................................ 1
6 c 1627200 Label (DuraMatch 2 Transmission) ..................................................................... 1
7 1589437 Label (DuraMatch Plus2 Transmission) .............................................................. 1
8 1335137 Label (Nameplate Tag) ....................................................................................... 1
9 1534660 Label (Patents and Trademarks) ........................................................................ 1
10 2074209 Label (Parking Brake Warning) ........................................................................... 1
11 1324480 Label (Battery Switch) ......................................................................................... 1

FOOTNOTES:
a Basic Transmission c Electric Transmission
b Contact Your Local Hyster Dealer

©2011 HYSTER COMPANY See Service Manual 1-61

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

LABELS (FIGURE 1-27)

EXTERIOR

1-62 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

LABELS
EXTERIOR

ITEM PART NO. DESCRIPTION QTY

1 1330919 Label (Mast Warning) ......................................................................................... 1
2 1330917 Label (Operator Restraint) .................................................................................. 2
3 b. . . . . Label (Impact Rating) ....................................................................................... 1
4 2073197 Label (Operator Warning) ................................................................................... 1
5 c 2034459 Label (Ether Warning) ......................................................................................... 1
6 1501259 Nameplate (LP Tank) .......................................................................................... 1
7 170658 Rivet ................................................................................................................... 4
8 1354171 Label (Flammable LPG) ...................................................................................... 1
9 2074255 Label (Unleaded Fuel Only) ............................................................................. 1
9 2074256 Label (Fuel Fill) ................................................................................................... 1
10 g 1566953 Plate (Hyster Logo) ............................................................................................. 1
10 i 1677428 Label (Hyster Logo) .......................................................................................... 1
10 a 1490398 Label (Hyster) ..................................................................................................... 1
11 g 1566951 Fastener .............................................................................................................. 2
12 1375676 Label (Boron-Free Antifreeze) ............................................................................ 1
13 1345939 Label (Fan Warning) ........................................................................................... 2
14 1325271 Label (Fan Warning) ........................................................................................... 1
15 1354165 Label (Antifreeze) .............................................................................................. 2
16 1594804 Label (Model 80) ................................................................................................. 2
16 1594805 Label (Model 100) ............................................................................................... 2
16 1594806 Label (Model 120) .............................................................................................. 2
17 1586439 Label (Fortis) ..................................................................................................... 2
18 1586440 Label (Hyster) .................................................................................................... 4
19 154066 Label (Type LPS) ................................................................................................ 2
19 154067 Label (Type DS) .................................................................................................. 2
20 1330920 Label (No Riders) ................................................................................................ 2
21 1335129 Label (Pinch Point) ............................................................................................. 2
22 e 2075615 Label (Hood Opening) ........................................................................................ 1
22 d 2076169 Label (Swivel Seat) ............................................................................................. 1
23 2075418 Label (Locking Gas Spring) ................................................................................ 1
24 2074741 Label (Joystick Warning) .................................................................................... 1
25 b. . . . . Inspection Plate ................................................................................................ 1
26 170658 Rivet ................................................................................................................... 2
27 2075656 Label (Mast Warning) ......................................................................................... 2
28 1580788 Plate (Warning) ................................................................................................... 1
f 2109698 Label (Hydraulic Fluid Warning) ......................................................................... 1
fh 4603386 Label (Hydraulic Quick Disconnect) .................................................................... 1

FOOTNOTES:
a Box Car Special or Paper Roll Special Only f Not Illustrated
b Contact Your Local Hyster Dealer g → S/N G004V03649F
c Diesel Only h 4/2010 →
d For Vehicles With Swivel Seat Only i S/N G004V03650F →
e LPG Only

©2011 HYSTER COMPANY See Service Manual 1-63

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MINI LEVER MODULE LABELS (FIGURE 1-28)

HYDRAULIC CONTROL FUNCTIONS

1-64 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MINI LEVER MODULE LABELS

HYDRAULIC CONTROL FUNCTIONS

ITEM PART NO. DESCRIPTION QTY

1 2102640 Label ................................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 1-65

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NOTES

1-66 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

2 ENGINES
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 2
ENGINES

DESCRIPTION PAGE

CAMSHAFT AND OIL PAN

GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-52
COIL ASSEMBLY
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-55
CYLINDER BLOCK
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-42
CYLINDER HEAD
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-46
ENGINE ASSEMBLY
GM 4.3L, GASOLINE AND LPG - SHEET 1 OF 3 ...................................................................................... 2-32
GM 4.3L, GASOLINE AND LPG - SHEET 2 OF 3 ...................................................................................... 2-36
GM 4.3L, GASOLINE AND LPG - SHEET 3 OF 3 ...................................................................................... 2-40
ENGINE COOLING SYSTEM
WITH BASIC TRANSMISSION AND DRY BRAKES (→ 11/2006) ............................................................ 2-8
WITH BASIC TRANSMISSION AND DRY BRAKES (11/2006 →) ............................................................ 2-12
WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (11/2006 →) ............................. 2-20
WITH EXTERNAL OIL COOLER AND WITH ELECTRONIC TRANSMISSION - OR WITH WET
BRAKES (→ 11/2006) ................................................................................................................................ 2-16
ENGINE MOUNT
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-30
EXHAUST SYSTEM
GM 4.3L, GASOLINE AND LPG - WITH CATALYTIC CONVERTER ......................................................... 2-2
EXHAUST WRAPS
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-6
FAN MOUNT ASSEMBLY
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-24
FLYWHEEL AND HOUSING
GM 4.3L, GASOLINE AND LPG (→ S/N G004V02834E (ONE SPEED WITH WET BRAKE))
(→ S/N G004V02844E INC. 02874-02877, 02879-02880, 02882-02883, 02891, 02894-02896, 02898,
02901-02902 (ONE SPEED WITH DRY BRAKE))
(→ S/N G004V02842E (TWO SPEED WITH DRY BRAKE))
(→ S/N G004V02844E (TWO SPEED WITH WET BRAKE)) .................................................................... 2-26
GM 4.3L, GASOLINE AND LPG (S/N G004V02835E → (ONE SPEED WITH WET BRAKES))
(S/N G004V02845E → EXC. 02874-02877, 02879-02880, 02882-02883, 02891, 00289 (ONE SPEED
WITH DRY BRAKE)) (S/N G004V00284E → (TWO SPEED WITH DRY BRAKE))
(S/N G004V02847E → (TWO SPEED WITH WET BRAKE)) .................................................................... 2-28
OIL PUMP
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-56
VALVE COVER AND INLET MANIFOLD
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-48

©2011 HYSTER COMPANY See Service Manual 2-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

EXHAUST SYSTEM (FIGURE 2-1)

GM 4.3L, GASOLINE AND LPG — WITH CATALYTIC CONVERTER

2-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

EXHAUST SYSTEM
GM 4.3L, GASOLINE AND LPG – WITH CATALYTIC CONVERTER
KEY:
A: S100-120FT, 120SFT, 120PRS
B: S80FT, 80BSC, 100BCS
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1618227 Exhaust Pipe .............................................................................................. 1 1
1 a 1598499 Exhaust Pipe .............................................................................................. .. 1
1 1677528 Exhaust Pipe (2010 Series) ..................................................................... 1 1
2 30370 Clamp ........................................................................................................ 1 1
3 df 2072202 Muffler (Welded) ......................................................................................... 1 1
3 d 2078353 Muffler (Crimped) ..................................................................................... 1 1
3 d 2072202 Muffler (Welded) (Safety) ........................................................................... 1 1
3 ag 2090664 Muffler (Catalyzed) ..................................................................................... .. 1
3 ai 2098588 Muffler (Catalyzed) ..................................................................................... .. 1
3 4601153 Catalytic Converter (2010 Series) .............................................................. .. 1
4 1510115 Capscrew .................................................................................................. 2 2
5 h 1528938 Washer ....................................................................................................... 4 4
6 h 1528930 Mount ......................................................................................................... 2 2
6 j 1709996 Isolator ...................................................................................................... 4 4
7 h 1532585 Washer ....................................................................................................... 1 1
8 h 1649471 Spacer ........................................................................................................ 2 2
8 j 1708371 Spacer ....................................................................................................... 2 2
9 1582222 Locknut ..................................................................................................... 2 2
10 1402189 Gasket ....................................................................................................... 1 1
11 1639845 Exhaust Pipe .............................................................................................. 1 ..
11 1677600 Exhaust Pipe (Alternate Part) ..................................................................... 1 ..
11 1639679 Exhaust Pipe .............................................................................................. .. 1
11 1677530 Exhaust Pipe (Alternate Part) ..................................................................... .. 1
11 4006455
4021209 Exhaust Pipe (2010 Series) ....................................................................... .. 1
11 4006456
4020857 Exhaust Pipe (2010 Series) ..................................................................... 1 ..
12 1469405 Nut ............................................................................................................. 2 2
13 292683 Lockwasher .............................................................................................. 2 2
14 1580028 Gasket ....................................................................................................... 1 1
15 cd 2071327 Catalytic Converter (Non Box Car Speicals) .............................................. 1 1
15 bd 2098586 Catalytic Converter (Non Box Car Speicals) .............................................. 1 1
15 4601152 Catalytic Converter (Non Box Car Specials)(2010 series) ................... 1 1
16 1580027 Gasket ....................................................................................................... 1 1
17 1528482 Capscrew .................................................................................................. 2 2
18 1566528 Gasket ........................................................................................................ 2 2
18 4018959 Gasket (Alternate Part) ............................................................................ 2 2
19 1641627 Exhaust Pipe ............................................................................................. 1 1
20 1580092 Stud ............................................................................................................ 6 6
21 a 1580136 Locknut ..................................................................................................... .. 2
21 1580136 Locknut ..................................................................................................... 6 6
22 1580029 Gasket ........................................................................................................ 2 2
22 4006052 Gasket Alternate Part) ............................................................................. 2 2

©2011 HYSTER COMPANY See Service Manual 2-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

EXHAUST SYSTEM
GM 4.3L, GASOLINE AND LPG – WITH CATALYTIC CONVERTER
KEY:
A: S100-120FT, 120SFT, 120PRS
B: S80FT, 80BSC, 100BCS
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
23 1641629 Exhaust Pipe ............................................................................................. 1 1
24 1502543 Nut (Flange) .............................................................................................. 2 2
25 1639847 Exhaust Pipe .............................................................................................. .. 1
25 1677649 Exhaust Pipe ............................................................................................. .. 1
25 1639847 Exhaust Pipe .............................................................................................. 1 ..
25 a 1639849 Exhaust Pipe .............................................................................................. 1 1
25 1677648 Exhaust Pipe (2010 Series) ....................................................................... .. 1
25 1677649 Exhaust Pipe (2010 Series) ..................................................................... 1 ..
25 a 1677651 Exhaust Pipe (2010 Series) ....................................................................... .. 1
26 1460477 Nut ............................................................................................................. 4 4
27 1578825 Bracket ....................................................................................................... .. 1
27 1578873 Bracket ...................................................................................................... 1 ..
28 a 1402189 Gasket ....................................................................................................... .. 1
e 4006802 Sensor (Oxygen) ...................................................................................... 1 1

FOOTNOTES:
a Box Car Special Only f Optional
b Gasoline Only Up to 2008 and Gasoline and LPG g → S/N G004V02563E
2008 and Up h → S/N G004V04567G
c LPG and Gasoline Up To 2007, LPG 2007 to 2008 i S/N G004V02564E →
d Non Box Car Special j S/N G004V04568G →
e Not Illustrated

2-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 2-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

EXHAUST WRAPS (FIGURE 2-2)

GM 4.3L, GASOLINE AND LPG

2-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

EXHAUST WRAPS
GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

1 2094026 Wrap (Flex Joint) ................................................................................................ 1
2 2087121 Wrap (Joint) ........................................................................................................ 1
3 2087122 Exhaust Wrap (with Snaps) ................................................................................ 1
4 2073024 Wrap (Flex Joint) ................................................................................................ 1
5 2087119 Wrap (Joint) ........................................................................................................ 1
6 2094027 Exhaust Wrap ..................................................................................................... 1
7 2087117 Wrap (Manifold) .................................................................................................. 2
8 2087123 Exhaust Wrap (Y Joint) ....................................................................................... 1
9 b 2094028 Exhaust Wrap ..................................................................................................... 1
9 a 2094029 Exhaust Wrap ..................................................................................................... 1
ac 2089364 Boot (Spark Plug) ............................................................................................... 6
c 1702713 Heat Shield (Spark Plug) (Alternate Part) ........................................................... 6

FOOTNOTES:
a 80 BCS Only c Not Illustrated
b All Except BCS

©2011 HYSTER COMPANY See Service Manual 2-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE COOLING SYSTEM (FIGURE 2-3)

WITH BASIC TRANSMISSION AND DRY BRAKES (→ 11/2006)

2-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ENGINE COOLING SYSTEM

WITH BASIC TRANSMISSION AND DRY BRAKES (→ 11/2006)

ITEM PART NO. DESCRIPTION QTY

1 d 1578931 Bracket ................................................................................................................ 1
1 e 1676151 Mounting Weldment ............................................................................................ 1
2 1530243 Insert ................................................................................................................... 4
3 1583611 Capscrew ............................................................................................................ 4
4 2065853 Radiator .............................................................................................................. 1
4 1569079 Drain Valve (w/Thread Wrap) ......................................................................... 1
5 1534417 Capscrew ............................................................................................................ 4
6 1476421 Washer ............................................................................................................... 4
7 302399 Nut ...................................................................................................................... 4
8 bc 1623711 Baffle (LH) ........................................................................................................... 1
9 1480237 Nut ...................................................................................................................... 10
10 1527879 Capscrew ............................................................................................................ 10
11 c 1578974 Baffle ................................................................................................................... 1
11 b 1579242 Baffle (LH) ........................................................................................................... 1
12 b 1579235 Baffle (LH) ........................................................................................................... 1
13 1551663 Clip ...................................................................................................................... 2
14 119236 Clamp ................................................................................................................. 3
15 d 2071617 Radiator Hose (Lower) ........................................................................................ 1
15 e 2102314 Radiator Hose (Lower) ........................................................................................ 1
16 369804 Clamp ................................................................................................................. 1
17 d 2071616 Radiator Hose (Upper) ........................................................................................ 1
17 e 2071618 Radiator Hose (Upper) ........................................................................................ 1
18 c 1578977 Baffle ................................................................................................................... 1
18 b 1579240 Baffle (RH) .......................................................................................................... 1
19 b 1579244 Baffle (RH) .......................................................................................................... 1
20 1571640 Shroud ................................................................................................................ 1
21 14385 Fitting .................................................................................................................. 1
22 1302955 Hose ................................................................................................................... 1
23 369815 Clamp ................................................................................................................. 2
24 340204 Strap ................................................................................................................... 1
25 1648941 Bracket ................................................................................................................ 1
26 344432 Reservoir ............................................................................................................ 1
27 302023 Screw .................................................................................................................. 2
28 320154 Washer ............................................................................................................... 2
29 1535257 Nut ...................................................................................................................... 2
30 345455 Outlet Assembly .................................................................................................. 1
30 339735 Hose ............................................................................................................... 1
30 345453 Outlet (Reservoir) ........................................................................................... 1
30 345454 Cap ................................................................................................................. 1
30 336550 Bushing .......................................................................................................... 1
31 bc 1623710 Baffle (RH) .......................................................................................................... 1
32 1352140 Radiator Cap ....................................................................................................... 1
33 1529787 Isolator ................................................................................................................ 4
34 246108 Sealant ................................................................................................................ AR
35 1574286 Screen ................................................................................................................ 1
a 1531404 Sensor (Low Coolant Level) ............................................................................... 1

©2011 HYSTER COMPANY See Service Manual 2-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a Not Illustrated
b S100FT, S100FTBCS, S120FT, S120FTPRS
c S80FT, S80FTBCS
d → S/N G004V04287G
e S/N G004V04288G →

2-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 2-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE COOLING SYSTEM (FIGURE 2-4)

WITH BASIC TRANSMISSION AND DRY BRAKES (11/2006 →)

2-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ENGINE COOLING SYSTEM

WITH BASIC TRANSMISSION AND DRY BRAKES (11/2006 →)

ITEM PART NO. DESCRIPTION QTY

1 d 1578931 Bracket ................................................................................................................ 1
1 g 1676151 Mounting Weldment ............................................................................................ 1
2 1530243 Insert ................................................................................................................... 4
3 1583611 Capscrew ............................................................................................................ 4
4 2065853 Radiator .............................................................................................................. 1
4 1569079 Drain Valve (w/Thread Wrap) ......................................................................... 1
5 1527876 Capscrew ............................................................................................................ 4
6 1476421 Washer ............................................................................................................... 4
7 302399 Nut ...................................................................................................................... 4
8 bc 1623711 Baffle (LH) ........................................................................................................... 1
9 b 1480237 Nut ...................................................................................................................... 8
10 b 1527879 Capscrew ............................................................................................................ 8
11 b 1579242 Baffle (LH) ........................................................................................................... 1
11 c 1578974 Baffle (LH) ........................................................................................................... 1
12 b 1579235 Baffle (LH) ........................................................................................................... 1
13 1551663 Clip ...................................................................................................................... 2
14 119236 Clamp ................................................................................................................. 3
15 d 2071617 Radiator Hose (Lower) ........................................................................................ 1
15 g 2102314 Radiator Hose (Lower) ........................................................................................ 1
16 369804 Clamp ................................................................................................................. 1
17 d 2071616 Radiator Hose (Upper) ........................................................................................ 1
17 g 2071618 Radiator Hose (Upper) ........................................................................................ 1
18 b 1579240 Baffle (RH) .......................................................................................................... 1
18 c 1578977 Baffle (RH) .......................................................................................................... 1
19 b 1579244 Baffle (RH) .......................................................................................................... 1
20 1611442 Shroud ................................................................................................................ 1
21 14385 Fitting .................................................................................................................. 1
22 1302955 Hose ................................................................................................................... 1
23 369815 Clamp ................................................................................................................. 2
24 1643342 Reservoir ............................................................................................................ 1
24 4022937 Seal (Not Illustrated) ........................................................................................... 1
25 1672910 Screen ................................................................................................................ 1
25 4003844 Screen (Alternate Part) ....................................................................................... 1
25 a 4006347 Channel (Left) ..................................................................................................... 1
25 a 4006348 Channel (Right) ................................................................................................... 1
26 302023 Screw .................................................................................................................. 2
27 320154 Washer ............................................................................................................... 2
28 1535257 Nut ...................................................................................................................... 2
29 345455 Outlet Assembly .................................................................................................. 1
29 339735 Hose ............................................................................................................... 1
29 345453 Outlet (Reservoir) ........................................................................................... 1
29 345454 Cap ................................................................................................................. 1
29 336550 Bushing .......................................................................................................... 1
30 bc 1623710 Baffle (RH) .......................................................................................................... 1
31 1529787 Isolator ................................................................................................................ 4
32 246108 Sealant ................................................................................................................ AR
33 1352140 Radiator Cap ....................................................................................................... 1
34 ef 1672824 Exhaust Shield .................................................................................................... 1
a 1531404 Sensor (Low Coolant Level) ............................................................................... 1

©2011 HYSTER COMPANY See Service Manual 2-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a Not Illustrated e S/N G004V03744F → WITH EXHAUST PIPE P/N
b S100FT, S100FTBCS, S120FT, S120FTPRS 1677648
c S80FT, S80FTBCS f S/N G004V03784F → WITH EXHAUST PIPE P/N
d → S/N G004V04287G 1677649
g S/N G004V04288G →

2-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 2-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE COOLING SYSTEM (FIGURE 2-5)

WITH EXTERNAL OIL COOLER AND WITH ELECTRONIC TRANSMISSION — OR WITH WET BRAKES
(→ 11/2006)

2-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ENGINE COOLING SYSTEM

WITH EXTERNAL OIL COOLER AND WITH ELECTRONIC TRANSMISSION – OR WITH WET BRAKES
(→ 11/2006)

ITEM PART NO. DESCRIPTION QTY

1 d 1578931 Bracket ................................................................................................................ 1
1 e 1676151 Mounting Weldment (Alternate Part) .............................................................. 1
2 1530243 Insert .................................................................................................................. 4
3 1583611 Capscrew ........................................................................................................... 4
4 2066322 Radiator (Assembly) ......................................................................................... 1
4 1623821 Radiator ......................................................................................................... 1
4 1623819 Oil Cooler ...................................................................................................... 1
5 1527876 Capscrew ........................................................................................................... 4
6 1476421 Washer ............................................................................................................... 4
7 302399 Nut ...................................................................................................................... 4
8 bc 1623711 Baffle (LH) .......................................................................................................... 1
9 c 1578974 Baffle (LH) ........................................................................................................... 1
9 b 1579242 Baffle (LH) ........................................................................................................... 1
10 14385 Fitting ................................................................................................................. 1
11 cd 1551663 Clip ...................................................................................................................... 2
11 e 1693705 Clip ..................................................................................................................... 2
12 c 1578977 Baffle (RH) .......................................................................................................... 1
12 b 1579244 Baffle (RH) .......................................................................................................... 1
13 119236 Clamp ................................................................................................................. 3
14 2071619 Radiator Hose ................................................................................................... 1
15 369804 Clamp ................................................................................................................. 1
16 2071618 Radiator Hose ................................................................................................... 1
17 369815 Clamp ................................................................................................................. 2
18 1302955 Hose ................................................................................................................... 1
19 340204 Strap ................................................................................................................... 1
20 1648941 Bracket ................................................................................................................ 1
21 c 1480237 Nut ...................................................................................................................... 4
21 b 1480237 Nut ...................................................................................................................... 8
22 c 1527879 Capscrew ........................................................................................................... 4
22 b 1527879 Capscrew ........................................................................................................... 8
23 344432 Reservoir ............................................................................................................ 1
24 d 1611444 Shroud ................................................................................................................ 1
24 e 2098121 Shroud ............................................................................................................... 1
25 d 302023 Screw .................................................................................................................. 2
25 e 302024 Screw ................................................................................................................. 4
26 d 320154 Washer ............................................................................................................... 2
26 e 320154 Washer ............................................................................................................... 4
27 345455 Outlet Assembly ............................................................................................... 1
27 339735 Hose ............................................................................................................... 1
27 345453 Outlet (Reservoir) ......................................................................................... 1
27 345454 Cap ................................................................................................................. 1
27 336550 Bushing ......................................................................................................... 1
28 bc 1623710 Baffle (RH) ......................................................................................................... 1
29 d 1535257 Nut ...................................................................................................................... 2
29 e 1535257 Nut ...................................................................................................................... 4
30 1352140 Radiator Cap ..................................................................................................... 1
31 1529787 Isolator ............................................................................................................... 4
32 1574286 Screen ................................................................................................................ 1
33 246108 Sealant ............................................................................................................... AR

©2011 HYSTER COMPANY See Service Manual 2-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE COOLING SYSTEM

WITH EXTERNAL OIL COOLER AND WITH ELECTRONIC TRANSMISSION – OR WITH WET BRAKES
(→ 11/2006)

ITEM PART NO. DESCRIPTION QTY

34 b 1579235 Baffle (LH) ........................................................................................................... 1
35 b 1579240 Baffle (RH) .......................................................................................................... 1
ae 1676093 Cover .................................................................................................................. 1
a 1531404 Sensor (Low Coolant Level) ............................................................................... 1

FOOTNOTES:
a Not Illustrated d → S/N G004V04287G
b S100FT, S100FTBCS, S120FT, S120FTPRS e S/N G004V04288G →
c S80FT, S80FTBCS

2-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 2-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE COOLING SYSTEM (FIGURE 2-6)

WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (11/2006 →)

2-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ENGINE COOLING SYSTEM

WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (11/2006 →)

ITEM PART NO. DESCRIPTION QTY

2066322 Radiator (Assembly) ......................................................................................... 1
1 1623821 Radiator ......................................................................................................... 1
1 1623819 Oil Cooler ...................................................................................................... 1
1 1597795
1569080 Screw ............................................................................................................. 4
2 1352140 Radiator Cap ..................................................................................................... 1
3 1676151 Mounting Weldment ......................................................................................... 1
4 1529787 Isolator ............................................................................................................... 4
5 1583611 Capscrew ........................................................................................................... 4
6 1530243 Insert .................................................................................................................. 4
7 1672824 Exhaust Shield .................................................................................................. 1
8 2071619 Radiator Hose ................................................................................................... 1
9 119236 Clamp ................................................................................................................. 3
10 1693705 Clip ..................................................................................................................... 2
11 2071618 Radiator Hose ................................................................................................... 1
12 369804 Clamp ................................................................................................................. 1
13 1643342 Reservoir ........................................................................................................... 1
14 345455 Outlet Assembly ............................................................................................... 1
15 345453 Outlet (Reservoir) ......................................................................................... 1
15 4022937 Seal (Not Illustrated)(Alternate Part) .......................................................... 1
16 345454 Cap ................................................................................................................. 1
17 336550 Bushing ......................................................................................................... 1
18 1663877 Hose ............................................................................................................... 1
19 1302955 Hose ................................................................................................................... 1
20 369815 Clamp ................................................................................................................. 2
21 1695670 Plate .................................................................................................................... 1
22 1535257 Nut ...................................................................................................................... 4
23 320154 Washer ............................................................................................................... 4
24 302024 Screw ................................................................................................................. 4
25 b 1672910 Screen ................................................................................................................ 1
25 d 4003844 Screen ................................................................................................................ 1
26 c 1676122 Channel .............................................................................................................. 1
26 e 4006347 Channel .............................................................................................................. 1
27 c 1676123 Channel .............................................................................................................. 1
27 e 4006348 Channel .............................................................................................................. 1
28 222036 Rivet .................................................................................................................... 6
29 1476421 Washer ............................................................................................................... 8
30 1684276 Bracket ................................................................................................................ 1
31 2098121 Shroud ............................................................................................................... 1
32 302399 Nut ...................................................................................................................... 4
33 1476421 Washer ............................................................................................................... 4
34 1623710 Baffle .................................................................................................................. 1
35 1527876 Capscrew ........................................................................................................... 4
36 1623711 Baffle .................................................................................................................. 1
a 14385 Fitting ................................................................................................................. 1
246108 Sealant ............................................................................................................... AR

©2011 HYSTER COMPANY See Service Manual 2-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a Not Illustrated
b → PENDING PER ECN 10489702
c → PENDING PER ECN 10489709
d PENDING PER ECN 10489702 →
e PENDING PER ECN 10489709 →

2-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 2-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FAN MOUNT ASSEMBLY (FIGURE 2-7)

GM 4.3L, GASOLINE AND LPG

2-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FAN MOUNT ASSEMBLY

GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

1583769 Fan Mount Assembly ........................................................................................ 1
1 1615817 Bracket .......................................................................................................... 1
2 1615920 Ball Bearing .................................................................................................. 1
3 2014670 Bearing .......................................................................................................... 1
4 1615818 Spacer ........................................................................................................... 1
5 2083634 Shaft .............................................................................................................. 1
6 15180 Washer .......................................................................................................... 1
7 292559 Capscrew ...................................................................................................... 1
8 1502093
12921 Snap Ring ...................................................................................................... 1
9 360387 Loctite ............................................................................................................ AR

©2011 HYSTER COMPANY See Service Manual 2-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FLYWHEEL AND HOUSING (FIGURE 2-8)

GM 4.3L, GASOLINE AND LPG (→ S/N G004V02834E (ONE SPEED WITH WET BRAKE))
(→ S/N G004V02844E INC. 02874-02877, 02879-02880, 02882-02883, 02891, 02894-02896, 02898, 02901-02902
(ONE SPEED WITH DRY BRAKE)) (→ S/N G004V02842E (TWO SPEED WITH DRY BRAKE))
(→ S/N G004V02844E (TWO SPEED WITH WET BRAKE))

2-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FLYWHEEL AND HOUSING

GM 4.3L, GASOLINE AND LPG (→ S/N G004V02834E (ONE SPEED WITH WET BRAKE))
(→ S/N G004V02844E INC. 02874-02877, 02879-02880, 02882-02883, 02891, 02894-02896, 02898, 02901-02902
(ONE SPEED WITH DRY BRAKE)) (→ S/N G004V02842E (TWO SPEED WITH DRY BRAKE))
(→ S/N G004V02844E (TWO SPEED WITH WET BRAKE))

ITEM PART NO. DESCRIPTION QTY

1 303150 Dowel ................................................................................................................. 2
2 292515 Capscrew ........................................................................................................... 15
3 1627227 Flywheel .............................................................................................................. 1
4 1460477 Nut ...................................................................................................................... 1
5 1565832 Bracket ............................................................................................................... 1
6 240072 Static Strap ........................................................................................................ 1
7 1586013 Capscrew ........................................................................................................... 1
8 1456112 Bolt ..................................................................................................................... 6
9 1338222 Pin ...................................................................................................................... AR
10 375571 Pin ...................................................................................................................... 1
11 1627345 Bearing .............................................................................................................. 1
12 1553269 Housing ............................................................................................................. 1
13 1623092 Bracket (Tube Retention) .................................................................................... 1
14 388049
292682 Lockwasher ....................................................................................................... 19
15 292517 Capscrew ............................................................................................................ 4
16 1624204 Bracket (Electrical Connector) ............................................................................ 1

©2011 HYSTER COMPANY See Service Manual 2-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FLYWHEEL AND HOUSING (FIGURE 2-9)

GM 4.3L, GASOLINE AND LPG (S/N G004V02835E → (ONE SPEED WITH WET BRAKES))
(S/N G004V02845E → EXC. 02874-02877, 02879-02880, 02882-02883, 02891, 00289 (ONE SPEED WITH DRY
BRAKE)) (S/N G004V00284E → (TWO SPEED WITH DRY BRAKE))
(S/N G004V02847E → (TWO SPEED WITH WET BRAKE))

2-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FLYWHEEL AND HOUSING

GM 4.3L, GASOLINE AND LPG (S/N G004V02835E → (ONE SPEED WITH WET BRAKES))
(S/N G004V02845E → EXC. 02874-02877, 02879-02880, 02882-02883, 02891, 00289 (ONE SPEED WITH DRY
BRAKE)) (S/N G004V00284E → (TWO SPEED WITH DRY BRAKE))
(S/N G004V02847E → (TWO SPEED WITH WET BRAKE))

ITEM PART NO. DESCRIPTION QTY

1 303150 Dowel ................................................................................................................. 2
2 292515 Capscrew ........................................................................................................... 18
3 1627227 Flywheel .............................................................................................................. 1
4 1460477 Nut ...................................................................................................................... 1
5 1565832 Bracket ............................................................................................................... 1
6 240072 Static Strap ........................................................................................................ 1
7 1586013 Capscrew ........................................................................................................... 1
8 1456112 Bolt ..................................................................................................................... 6
9 1338222 Pin ...................................................................................................................... AR
10 375571 Pin ...................................................................................................................... 1
11 1627345 Bearing .............................................................................................................. 1
12 1553269 Housing ............................................................................................................. 1
13 1660913 Bracket (Tube Retention) ................................................................................. 1
14 388049
292682 Lockwasher ....................................................................................................... 19
15 1654415 Bracket (Electrical Connector) ............................................................................ 1
16 1623093 Bracket ............................................................................................................... 1
17 1500912 Clip ..................................................................................................................... 2
18 1531480 Clip ..................................................................................................................... 1
19 1582464 Fastener ............................................................................................................. 3

©2011 HYSTER COMPANY See Service Manual 2-29

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE MOUNT (FIGURE 2-10)

GM 4.3L, GASOLINE AND LPG

2-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ENGINE MOUNT
GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

1 1590397 Mount (LH) ......................................................................................................... 1
1 1590399 Mount (RH) ........................................................................................................ 1
2 1597842 Bracket (Crossmember) ...................................................................................... 1
2 1673981 Bracket (Crossmember) (Alternate Part) ........................................................ 1
3 293699 Capscrew ........................................................................................................... 2
4 1504075 Washer ............................................................................................................... 2
5 1557737 Washer ............................................................................................................... 4
6 2069951 Isolator ............................................................................................................... 4
7 1565453 Nut (Flange) ....................................................................................................... 2
8 303150 Dowel ................................................................................................................. 2
9 1591666 Capscrew ........................................................................................................... 4
10 1565195 Capscrew ........................................................................................................... 6
11 1566853 Capscrew ........................................................................................................... 4

©2011 HYSTER COMPANY See Service Manual 2-31

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE ASSEMBLY (FIGURE 2-11)

GM 4.3L, GASOLINE AND LPG — SHEET 1 OF 3

2-32 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ENGINE ASSEMBLY
GM 4.3L, GASOLINE AND LPG – SHEET 1 OF 3

ITEM PART NO. DESCRIPTION QTY

1539198 Engine Assy-Gas (2006 Series) ......................................................................... 1
b 1646673 Engine Assy-Gas (2007 Series) ......................................................................... 1
e 1649504 Engine Assy-Gas (2008 Series) ......................................................................... 1
1694587 Engine Assy-Gas (2009 Series) ......................................................................... 1
4004339 Engine Assy -Gas (2010 Series) ........................................................................ 1
4020186 Engine Assy (Gas) (2011 Series) (Gas 2011) .................................................. 1
1591677 Engine Assy-LPG (2006 Series) ......................................................................... 1
a 1646674 Engine Assy-LPG (2007 Series) ......................................................................... 1
d 1649334 Engine Assy-LPG (2008 Series) ......................................................................... 1
1694586 Engine Assy-LPG (2009 Series) ......................................................................... 1
4004338 Engine Assy -LPG (2010 Series) ........................................................................ 1
4019146 Engine Assy (LPG)(2010) (Heavy Duty, Optional) ............................................. 1
4020187 Engine Assy (LPG) (2011 series) ....................................................................... 1
4020186 Engine Assy (Gas) (2011 Series) ..................................................................... 1
4020187 Engine Assy (LPG) (LPG 2011) .......................................................................... 1
1 1514429 Nut ...................................................................................................................... 6
2 1527877 Capscrew ........................................................................................................... 6
3 ..... Spark Plug Wire Harness (LH) ......................................................................... 1
4 1628117 Clamp ................................................................................................................. 2
5 1626519 Bracket (2006 Series) ......................................................................................... 1
5 1641371 Bracket (2007-2011 Series) .............................................................................. 1
6 1564035 Bracket ............................................................................................................... 2
7 1544212 Bracket ................................................................................................................ 1
8 1460477 Nut ...................................................................................................................... 5
9 1578620 Stud .................................................................................................................... 2
10 388049
292682 Lockwasher ....................................................................................................... 3
11 16634 Capscrew ........................................................................................................... 3
12 1305165 Washer ............................................................................................................... 1
13 221544 Capscrew ........................................................................................................... 1
14 1377750 Pulley ................................................................................................................. 1
15 1572111 Spacer (2006 Series) .......................................................................................... 1
15 1453247 Spacer (2007 Series) .......................................................................................... 1
15 1676453 Spacer (2008-2011) ........................................................................................... 1
16 c 2085641 Fan (2006-2007 Series) ...................................................................................... 1
16 f 2099479 Fan (2008-2011 Series) ..................................................................................... 1
17 296418 Washer ............................................................................................................... 4
18 293625 Capscrew ........................................................................................................... 4
19 1527879 Capscrew ........................................................................................................... 4
20 1583769 Fan Mount Assembly (FFigure 2-7)................................................................ 1
21 1578617 Stud .................................................................................................................... 2
22 2090303 Belt Tensioner ................................................................................................... 1
23 1578619 Stud .................................................................................................................... 1
24 1527885 Capscrew ........................................................................................................... 1
25 2090051 V-Belt (Serpentine 6 Rib Micro) ....................................................................... 1
26 1528482 Capscrew ........................................................................................................... 1
27 1636803 Bracket (Alternator) .......................................................................................... 1
28 1560200 Thermostat Housing ......................................................................................... 1
29 1569540 Thermostat (Bypass Type 197 Degree With Seal) ......................................... 1
30 ..... Spark Plug Wire Harness (RH) ........................................................................ 1

©2011 HYSTER COMPANY See Service Manual 2-33

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE ASSEMBLY
GM 4.3L, GASOLINE AND LPG – SHEET 1 OF 3

ITEM PART NO. DESCRIPTION QTY

31 1534017 Alternator ........................................................................................................... 1
32 2071579 Fan Pulley (Fan) ................................................................................................ 1
33 1529366 Capscrew ........................................................................................................... 2
34 1554814 Spacer ................................................................................................................ 1
35 1327647 Capscrew ........................................................................................................... 1
36 2063017 Pulley (Water Pump) ......................................................................................... 1
37 320157 Washer ............................................................................................................... 1
38 302400 Nut ...................................................................................................................... 1
39 1623917 Manifold (Exhaust) ............................................................................................ 2
39 4008610 Exhaust Manifold (Heavy Duty) (2010 Series) .................................................... 2
40 1623895 Shield .................................................................................................................. 2
41 1316487 Shield ................................................................................................................. 1
42 1383257 Bolt ..................................................................................................................... 12
43 1539274 Gasket (Exhaust) .............................................................................................. 2
44 133696 Clamp ................................................................................................................. 1
45 ab 1514915 Dipstick Tube (2006-2007 Series) ...................................................................... 1
45 de 1671271 Dipstick Tube (2008-2011 Series) .................................................................... 1
46 ab 1510649 Dipstick ............................................................................................................... 1
46 de 1676923 Dipstick .............................................................................................................. 1
47 1316488 Shield ................................................................................................................. 2
48 1539273 Gasket ................................................................................................................ 2
49 1560255 Sensor (Coolant Temperature) ........................................................................ 1
50 246108 Sealant ............................................................................................................... AR
51 1510113 Capscrew ........................................................................................................... 2
52 1583602 Adapter (Gasoline, 2006 Series) ........................................................................ 1
52 b 1657558 Adapter (Gasoline, 2007 Series) ........................................................................ 1
52 e 1654872 Adapter (Gasoline) (2008-2011) ....................................................................... 1
52 a 1583601 Adapter (LPG) (2006-2007 Series) ..................................................................... 1
52 d 1654871 Adapter (LPG) (2008-2011) ................................................................................ 1
52 1560193 Sleeve ............................................................................................................ 2
53 2067592 Gasket (2006-2007 Series) ................................................................................. 1
53 1669426 Gasket (2008-2011 Series) ............................................................................... 1
54 1527876 Capscrew ........................................................................................................... 2
2088997 Kit-Ignition Cable (Spark Plug Wires and Coil Wire) (2006 Series) (Includes
Items 3, 30) ......................................................................................................... 1

FOOTNOTES:
a → S/N G004V02853E (LPG) d S/N G004V02854E → (LPG)
b → S/N G004V03165E (Gasoline) e S/N G004V03166E → (Gasoline)
c → S/N G004V04287G f S/N G004V04288G →

2-34 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 2-35

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE ASSEMBLY (FIGURE 2-12)

GM 4.3L, GASOLINE AND LPG — SHEET 2 OF 3

2-36 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ENGINE ASSEMBLY
GM 4.3L, GASOLINE AND LPG – SHEET 2 OF 3
KEY:
A: Gasoline
B: LPG
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1539198 Engine Assy-Gas (2006 Series) ................................................................. 1 ..
1646673 Engine Assy-Gas (2007 Series) ................................................................. 1 ..
1649504 Engine Assy-Gas (2008 Series) ................................................................. 1 ..
1694587 Engine Assy-Gas (2009 Series) ................................................................. 1 ..
4004339 Engine Assy -Gas (2010 Series) ................................................................ 1 ..
4020186 Engine Assy (Gas) (2011 Series) ............................................................ 1 ..
1591677 Engine Assy-LPG (2006 Series) ................................................................ .. 1
1646674 Engine Assy-LPG (2007 Series) ................................................................ .. 1
1649334 Engine Assy-LPG (2008 Series) ................................................................ .. 1
1694586 Engine Assy-LPG (2009 Series) ................................................................ .. 1
4004338 Engine Assy -LPG (2010 Series) ............................................................... .. 1
4019146 Engine Assy (LPG)(2010) (Heavy Duty, Optional) ..................................... .. 1
4020187 Engine Assy (LPG) (2011) ......................................................................... .. 1
1 1514429 Nut ............................................................................................................. 1 1
2 14387 Fitting ........................................................................................................ 1 ..
3 392620 Screw ......................................................................................................... 4 4
4 1552141 Filler Neck ................................................................................................. 1 1
5 1590201 Fitting ........................................................................................................ 1 1
6 246108 Sealant ...................................................................................................... AR AR
7 e 2087702 Wire Harness (Engine) (2006-2007 Series) (FFigure 4-38)...................... 1 ..
7 g 2093681 Wire Harness (Engine) (2008 - 2009 Series) (FFigure 4-39).................... 1 ..
7 h 4601159 Wire Harness (Engine) (2010 - 2011 Series) (FFigure 4-40)................ 1 ..
7 d 2087701 Wire Harness (Engine) (2006-2007 Series) (FFigure 4-41)...................... .. 1
7 f 2093682 Wire Harness (Engine) (2008 - 2009 Series) (FFigure 4-42).................... .. 1
7 h 4601160 Wire Harness (Engine) (2010 - 2011 Series) (FFigure 4-43).................... .. 1
8 1636048 Bracket ...................................................................................................... 1 1
9 1309993 Screw ......................................................................................................... 2 2
10 1566654 Pressure Transducer Sensor (Oil Pressure) ......................................... 1 1
11 1514429 Nut ............................................................................................................. 2 ..
12 1534417 Capscrew .................................................................................................. 3 3
13 a 2071560 Engine Control Module (2006 Series) ........................................................ .. 1
13 c 2071329 Engine Control Module (2006 Series) ........................................................ .. 1
13 b 2094097 Engine Control Module (2006/2007 Engine ECU) ..................................... .. 1
13 2101429 Engine Control Module (2008-2009 Engine ECU) ..................................... .. 1
13 4603426 Engine Control Module (2010 - 2011 Series) ............................................. .. 1
13 a 2071562 Engine Control Module (2006 Series) ........................................................ 1 ..
13 c 2071330 Engine Control Module (2006 Series) ........................................................ 1 ..
13 b 2094096 Engine Control Module (2006/2007 Series) ............................................... 1 ..
13 2101430 Engine Control Module (2008-2009 Engine ECU) ..................................... 1 ..
13 4603425 Engine Control Module (2010 - 2011 Series) ......................................... 1 ..
14 198675 Clamp ........................................................................................................ 2 ..
15 174413 Screw ......................................................................................................... 2 2
16 2080791 Bracket ....................................................................................................... 1 ..

©2011 HYSTER COMPANY See Service Manual 2-37

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE ASSEMBLY
GM 4.3L, GASOLINE AND LPG – SHEET 2 OF 3
KEY:
A: Gasoline
B: LPG
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
17 2081136 Tube ........................................................................................................... 1 ..
18 1552840 Tube ........................................................................................................... 1 ..
19 164488 Clamp ........................................................................................................ 1 ..
20 1309993 Screw ......................................................................................................... 2 2
21 1623860 Bracket ...................................................................................................... 1 ..
22 2062587 Hose .......................................................................................................... 1 ..
23 1564036 Retainer (Three Wire Clip) ....................................................................... 1 ..
24 168718 Clamp ........................................................................................................ 4 ..
25 2066137 Hose .......................................................................................................... 1 ..
26 1546285 Elbow (3/8 90 degree Elbow) ................................................................... 1 ..
27 1546283 Elbow (5/16 90 degree Elbow) ................................................................... 1 ..
28 1534417 Capscrew .................................................................................................. 1 ..
29 2081315 Adapter ...................................................................................................... 1 1
30 1636047 Bracket ....................................................................................................... 1 ..
31 1552840 Tube ........................................................................................................... 1 ..

FOOTNOTES:
a Basic Transmission e → S/N G004V03165E
b Both Electronic and Basic Transmissions f S/N G004V02854E ↔ S/N G004V04607H
c Electronic Transmission g S/N G004V03166E ↔ S/N G004V04607H
d → S/N G004V02853E h S/N G004V04608H → INC. 04572

2-38 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 2-39

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ENGINE ASSEMBLY (FIGURE 2-13)

GM 4.3L, GASOLINE AND LPG — SHEET 3 OF 3

2-40 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ENGINE ASSEMBLY
GM 4.3L, GASOLINE AND LPG – SHEET 3 OF 3

ITEM PART NO. DESCRIPTION QTY

1539198 Engine Assy-Gas (2006 Series) ......................................................................... 1
1646673 Engine Assy-Gas (2007 Series) ......................................................................... 1
1649504 Engine Assy-Gas (2008 Series) ......................................................................... 1
1694587 Engine Assy-Gas (2009 Series) ......................................................................... 1
4004339 Engine Assy -Gas (2010 Series) ........................................................................ 1
4020186 Engine Assy (Gas) (2011 Series) ..................................................................... 1
1591677 Engine Assy-LPG (2006 Series) ......................................................................... 1
1646674 Engine Assy-LPG (2007 Series) ......................................................................... 1
1649334 Engine Assy-LPG (2008 Series) ......................................................................... 1
1694586 Engine Assy-LPG (2009 Series) ......................................................................... 1
4004338 Engine Assy -LPG (2010 Series) ........................................................................ 1
4019146 Engine Assy (LPG)(2010) (Heavy Duty, Optional) ............................................. 1
4020187 Engine Assy (LPG) ............................................................................................. 1
1 1501994 Hose Clamp ........................................................................................................ 2
1 a 1501994 Hose Clamp ........................................................................................................ 1
2 b 2076429 Hose ................................................................................................................... 1
3 d 2082657 Module (Injector Driver) ...................................................................................... 2
4 1514429 Nut ...................................................................................................................... 6
5 1527877 Capscrew ........................................................................................................... 6
6 b 1570597 Tube .................................................................................................................... 1
7 b 1593913 Tube .................................................................................................................... 1
8 b 1510116 Capscrew ............................................................................................................ 1
9 b 1579136 Fitting ................................................................................................................. 1
10 1593914 Cap ..................................................................................................................... 1
bc 1527876 Capscrew ........................................................................................................... 3

FOOTNOTES:
a Gasoline Engine Only c Not Illustrated
b LPG Engine d Used up through 2009 series

©2011 HYSTER COMPANY See Service Manual 2-41

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

CYLINDER BLOCK (FIGURE 2-14)

GM 4.3L, GASOLINE AND LPG

2-42 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

CYLINDER BLOCK
GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

1539198 Engine Assy-Gas (2006 Series) ......................................................................... 1
c 1646673 Engine Assy-Gas (2007 Series) ......................................................................... 1
e 1649504 Engine Assy-Gas (2008 Series) ......................................................................... 1
1694587 Engine Assy-Gas (2009 Series) ......................................................................... 1
4004339 Engine Assy -Gas (2010 Series) ........................................................................ 1
4020186 Engine Assy (Gas) (2011 Series) ..................................................................... 1
1591677 Engine Assy-LPG (2006 Series) ......................................................................... 1
b 1646674 Engine Assy-LPG (2007 Series) ......................................................................... 1
d 1649334 Engine Assy-LPG (2008 Series) ......................................................................... 1
1694586 Engine Assy-LPG (2009 Series) ......................................................................... 1
4004338 Engine Assy -LPG (2010 Series) ........................................................................ 1
4019146 Engine Assy (LPG)(2010) (Heavy Duty, Optional) ............................................. 1
4020187 Engine Assy (LPG) (2011 Series) ....................................................................... 1
1 ..... Short Block Assembly ................................................................................. 1
2 1390759 Kit-Piston (Standard) ............................................................................... 6
2 1390760 Kit-Piston (0.020 O/S) (0,5 mm) ............................................................... 6
2 1627183 Kit-Piston (0.005 in O/S) .......................................................................... 6
3 1390761 Kit-Piston Ring (Standard) ...................................................................... 6
3 1390765 Kit-Piston Ring (0.020 O/S) (0,5 mm) ...................................................... 6
4 1360179 Piston Rod ................................................................................................ 6
5 1360182 Bolt ........................................................................................................ 2
6 1330450 Nut ......................................................................................................... 2
7 1390770 Piston Rod Bearing (Connecting Rod) (Standard) ................................ 6
8 1460386 Crankshaft ................................................................................................ 1
9 388302 Plug ........................................................................................................... 3
10 263842 Bolt ............................................................................................................ 10
11 1558807 Kit-Crankshaft Bearing (Standard) ......................................................... 3
11 1460738 Kit-Crankshaft Bearing (0.020 in. O/S) (Crankshaft) ............................. 3
12 1309839 Bearing Set (0.010 in. O/S) (Crankshaft) ................................................ 1
13 1514968 Valve .......................................................................................................... 1
14 159977 Pin .............................................................................................................. 4
15 1374313 Plug ........................................................................................................... 1
16 1335499 Pin .............................................................................................................. 2
17 1451319 Key ................................................................................................................. 1
18 1500884 Gasket ........................................................................................................... 1
19 388302 Plug (2006 Series) ........................................................................................ 2
19 1514267 Plug (2007-2011 Series) ............................................................................... 2
20 375601 Pin (CR/SHF RR Seal Retainer) ................................................................... 1
21 1460330 Retainer ......................................................................................................... 1
22 1450555 Stud ........................................................................................................... 2
23 1460331 Seal ............................................................................................................ 1
24 375575 Bolt ................................................................................................................ 1
25 375602 Bolt ................................................................................................................ 1
26 1331341 Plug ................................................................................................................ 4
27 388313 Nut ................................................................................................................. 1
a 159971 Plug ................................................................................................................ 8

©2011 HYSTER COMPANY See Service Manual 2-43

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a Not Illustrated
b → S/N G004V02853E
c → S/N G004V03165E
d S/N G004V02854E →
e S/N G004V03166E →

2-44 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 2-45

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

CYLINDER HEAD (FIGURE 2-15)

GM 4.3L, GASOLINE AND LPG

2-46 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

CYLINDER HEAD
GM 4.3L, GASOLINE AND LPG
KEY:
A: Gasoline
B: LPG
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1539198 Engine Assy-Gas (2006 Series) ................................................................. 1 ..
b 1646673 Engine Assy-Gas (2007 Series) ................................................................. 1 ..
d 1649504 Engine Assy-Gas (2008 Series) ................................................................. 1 ..
1694587 Engine Assy-Gas (2009 Series) ................................................................. 1 ..
4004339 Engine Assy -Gas (2010 Series) ................................................................ 1 ..
4020186 Engine Assy (Gas) (2011 Series) ............................................................ 1 ..
1591677 Engine Assy-LPG (2006 Series) ................................................................ .. 1
a 1646674 Engine Assy-LPG (2007 Series) ................................................................ .. 1
c 1649334 Engine Assy-LPG (2008 Series) ................................................................ .. 1
1694586 Engine Assy-LPG (2009 Series) ................................................................ .. 1
4004338 Engine Assy -LPG (2010 Series) ............................................................... .. 1
4019146 Engine Assy (LPG)(2010) (Heavy Duty, Optional) ..................................... .. 1
4020187 Engine Assy (LPG) (2011 Series) .............................................................. .. 1
1 1471557 Cylinder Head ....................................................................................... 2 ..
1 1553964 Cylinder Head (2006 Series) ................................................................. .. 2
1 1653888 Cylinder Head (2007-2011 Series) (Includes Items 3-9) ....................... .. 2
1 4017128 Kit-Service (Head-LPG) (Heavy Duty with Intake Seat Insert) .............. .. 2
2 1389051 Bolt ........................................................................................................ 4 4
2 1471555 Rocker Arm (2006 Series) ..................................................................... 12 12
2 1653887 Rocker Arm (2007-2011 Series) .......................................................... 12 12
3 1377110 Valve Stop ............................................................................................ 24 24
4 1386194 Exhaust Valve ...................................................................................... 6 ..
4 1482701 Exhaust Valve ........................................................................................ .. 6
5 1386195 Inlet Valve ............................................................................................. 6 6
6 1393127 Cap ........................................................................................................ 12 12
7 1386197 Seal (Black) (Intake) ............................................................................. 6 6
8 1386198 Spring ................................................................................................... 12 ..
8 1689026 Spring .................................................................................................... .. 12
9 1460384 Seal (Orange) (Exhaust) ...................................................................... 6 6
10 1489643 Support (Rocker Arm) ......................................................................... 2 2

FOOTNOTES:
a → S/N G004V02853E c S/N G004V02854E →
b → S/N G004V03165E d S/N G004V03166E →

©2011 HYSTER COMPANY See Service Manual 2-47

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

VALVE COVER AND INLET MANIFOLD (FIGURE 2-16)

GM 4.3L, GASOLINE AND LPG

2-48 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

VALVE COVER AND INLET MANIFOLD

GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

1539198 Engine Assy-Gas (2006 Series) ......................................................................... 1
c 1646673 Engine Assy-Gas (2007 Series) ......................................................................... 1
e 1649504 Engine Assy-Gas (2008 Series) ......................................................................... 1
1694587 Engine Assy-Gas (2009 Series) ......................................................................... 1
4004339 Engine Assy -Gas (2010 Series) ........................................................................ 1
4020186 Engine Assy (Gas) (2011 Series) ..................................................................... 1
1591677 Engine Assy-LPG (2006 Series) ......................................................................... 1
b 1646674 Engine Assy-LPG (2007 Series) ......................................................................... 1
d 1649334 Engine Assy-LPG (2008 Series) ......................................................................... 1
1694586 Engine Assy-LPG (2009 Series) ......................................................................... 1
4004338 Engine Assy -LPG (2010 Series) ........................................................................ 1
4019146 Engine Assy (LPG)(2010) (Heavy Duty, Optional) ............................................. 1
4020187 Engine Assy (LPG) (2011 Series) ....................................................................... 1
1 1597705 Cover (LH) ..................................................................................................... 1
2 1389102 Cover (RH) ..................................................................................................... 1
3 1552141 Filler Neck ..................................................................................................... 1
3 bc 1374290 Cap ................................................................................................................. 1
3 de 1683749 Cap ................................................................................................................. 1
4 1559695 Distributor Assembly (FFigure 4-23)......................................................... 1
5 1334423 Gasket ........................................................................................................... 1
6 1374288 Grommet ....................................................................................................... 3
7 379407 Fitting ............................................................................................................ 1
8 1641492 Spark Plug ..................................................................................................... 6
9 1564670 Ignition Coil Assembly (FFigure 2-18)........................................................... 1
10 1383904 Grommet ....................................................................................................... 6
11 1374289 Bolt ................................................................................................................ 6
12 1627350 Intake Manifold (Lower) (2006-2007 Series) .................................................. 1
12 1627351 Intake Manifold (Upper) (2006 Series) ........................................................... 1
12 bc 1653886 Intake Manifold (Upper) (2007 Series) ........................................................... 1
12 de 1684098 Manifold Assy (2008-2011) .......................................................................... 1
12 de 1684085 Intake Manifold (Lower) ........................................................................... 1
12 de 1684099 Intake Manifold (Upper) ........................................................................... 1
12 1389093 Bolt ............................................................................................................ 8
12 1559570 Gasket ....................................................................................................... 1
13 1559567 Sensor (Temperature manifold absolute pressure) .................................. 1
14 1374293 Gasket ........................................................................................................... 2
15 a 1377792 Bolt (Long) .................................................................................................... 10
16 a 1377793 Bolt (Medium) ............................................................................................... 4
17 a 1377794 Bolt (Short) .................................................................................................... 12
18 1471559 Valve Lifter ..................................................................................................... 12
19 1389050 Guide ............................................................................................................. 2
20 1389051 Bolt ................................................................................................................ 2
21 1386189 Push Rod ....................................................................................................... 12
22 1386190 Cylinder Head Gasket .................................................................................. 1
23 1627354 Hose Assy ..................................................................................................... 1
24 1471557 Cylinder Head (Gasoline) (FFigure 2-15)................................................... 1
24 1553964 Cylinder Head (LPG) (2006 Series) (FFigure 2-15)...................................... 1
24 1653888 Cylinder Head (LPG) (2007-2011 Series) (FFigure 2-15)............................. 1
24 4017128 Kit-Service (Head-LPG) (Heavy Duty Engine) ............................................... 1
25 1471560 Clamp ............................................................................................................ 2

©2011 HYSTER COMPANY See Service Manual 2-49

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

VALVE COVER AND INLET MANIFOLD

GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

26 1514915 Dipstick Tube (2006-2007 Series) .................................................................. 1
26 de 1671271 Dipstick Tube (2008-2011 Series) ............................................................... 1
27 bc 1510649 Dipstick (2006-2007 Series) ........................................................................... 1
27 de 1676923 Dipstick (2008-2011 Series) ......................................................................... 1
28 133696 Clamp ............................................................................................................. 1
29 1600925 Fitting (90 Degree) ......................................................................................... 1
30 1675726 Hose Assy (PCV) ........................................................................................... 1
1386187 Kit-Gasket (The kit includes two intake manifold gaskets) (Intake
Manifold) ....................................................................................................... 1

FOOTNOTES:
a Quanity is listed for both heads. d S/N G004V02854E → (LPG)
b → S/N G004V02853E (LPG) e S/N G004V03166E → (Gasoline)
c → S/N G004V03165E (Gasoline)

2-50 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 2-51

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

CAMSHAFT AND OIL PAN (FIGURE 2-17)

GM 4.3L, GASOLINE AND LPG

2-52 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

CAMSHAFT AND OIL PAN

GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

1539198 Engine Assy-Gas (2006 Series) ......................................................................... 1
c 1646673 Engine Assy-Gas (2007 Series) ......................................................................... 1
e 1649504 Engine Assy-Gas (2008 Series) ......................................................................... 1
1694587 Engine Assy-Gas (2009 Series) ......................................................................... 1
4004339 Engine Assy -Gas (2010 Series) ........................................................................ 1
4020186 Engine Assy (Gas) (2011 Series) ..................................................................... 1
1591677 Engine Assy-LPG (2006 Series) ......................................................................... 1
b 1646674 Engine Assy-LPG (2007 Series) ......................................................................... 1
d 1649334 Engine Assy-LPG (2008 Series) ......................................................................... 1
1694586 Engine Assy-LPG (2009 Series) ......................................................................... 1
4004338 Engine Assy -LPG (2010 Series) ........................................................................ 1
4019146 Engine Assy (LPG)(2010) (Heavy Duty, Optional) ............................................. 1
4020187 Engine Assy (LPG) (2011 Series) ....................................................................... 1
1 1627196 Camshaft ....................................................................................................... 1
2 1374297 Pin .............................................................................................................. 1
3 bc 1471556 Kit-Repair Cable Chain ................................................................................... 1
3 de 1683675 Kit-Repair Cable Chain (Timing Chain) ...................................................... 1
3 ..... Timing Chain ............................................................................................ 1
4 ..... Sprocket .................................................................................................... 1
5 ..... Sprocket .................................................................................................... 1
6 1374301 Bolt ................................................................................................................ 3
7 1374299 Bolt ................................................................................................................ 2
8 1374298 Retainer ......................................................................................................... 1
9 1454955 Bearing .......................................................................................................... 2
10 1454957 Bearing .......................................................................................................... 1
11 1383257 Bolt ................................................................................................................ 4
12 1389100 Water Pump (2006 Series) ............................................................................. 1
12 bc 1653884 Water Pump (2007 Series) ............................................................................. 1
12 de 1683678 Water Pump (2008-2011 Series) .................................................................. 1
13 bc 263828 Gasket ........................................................................................................ 2
13 de 1683677 Gasket ....................................................................................................... 2
14 1460322 Gasket ........................................................................................................... 1
15 1374108 Bolt ................................................................................................................ 10
16 130845 Clamp ............................................................................................................ 1
17 1383263 Cap ................................................................................................................. 1
18 1374317 Bolt ................................................................................................................ 6
19 1374315 Kit-Gear (Balancer) ....................................................................................... 1
20 1339963 Bolt ................................................................................................................ 2
21 1374326 Retainer ......................................................................................................... 1
22 1374314 Bearing .......................................................................................................... 1
23 1377107 Shaft .............................................................................................................. 1
24 1451321 Bearing ...................................................................................................... 1
25 1374313 Plug ................................................................................................................ 2
26 375587 Fitting ............................................................................................................ 1
27 1320000 Oil Filter ......................................................................................................... 1
28 1386176 Engine Oil Pump (FFigure 2-19)................................................................. 1
29 bc 1471558 Oil Pan ............................................................................................................ 1
29 de 1683746 Oil Pan ........................................................................................................... 1
30 1460757 Screw ......................................................................................................... 1
30 1460758 Gasket ....................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 2-53

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

CAMSHAFT AND OIL PAN

GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

31 bc 1386184 Gasket ............................................................................................................ 1
31 de 1683744 Gasket ........................................................................................................... 1
32 1386183 Bolt ................................................................................................................ 10
33 1360178 Nut ................................................................................................................. 1
34 1514965 Bolt ................................................................................................................ 1
35 bc 1514963 Sensor (Crankshaft Position) ......................................................................... 1
35 de 1683747 Sensor (Crankshaft Position) ...................................................................... 1
36 1514964 O-Ring ........................................................................................................... 1
37 bc 1585183 Engine Cover (Front Cover) ........................................................................... 1
37 de 1683720 Engine Cover (Front Cover) ........................................................................ 1
37 1654480 Bracket ...................................................................................................... 1
37 1654481 Shoe .......................................................................................................... 1
38 1386179 Bolt ............................................................................................................ 4
39 1377103 Bolt ............................................................................................................ 2
40 1389092 Grommet ................................................................................................... 6
41 bc 1377104 Seal ............................................................................................................ 1
41 de 1374107 Seal ............................................................................................................ 1
42 1627199 Damper .......................................................................................................... 1
43 1514962 Ring (Crankshaft Position Sensor) ................................................................. 1
43 4004594 Ring (Crankshaft Position Sensor) (Alternate Part) .................................. 1
a 263827 Stud ................................................................................................................ 1
ade 1683721 Pin .................................................................................................................. 2
ade 1683722 Gasket (Engine Front Cover) ....................................................................... 1

FOOTNOTES:
a Not Illustrated d S/N G004V02854E → (LPG)
b → S/N G004V02853E (LPG) e S/N G004V03166E → (Gasoline)
c → S/N G004V03165E (Gasoline)

2-54 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

COIL ASSEMBLY (FIGURE 2-18)

GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

1564670 Ignition Coil Assembly ........................................................................................ 1
1578517 Bracket ........................................................................................................... 1
1371237 Bolt ................................................................................................................ 4
1578518 Module ............................................................................................................ 1
1578519 Heatsink ......................................................................................................... 1
1578520 Screw ............................................................................................................. 2
1578521 Ignition Coil ................................................................................................... 1
1374323 Nut ................................................................................................................. 1
1578522 Bracket .......................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 2-55

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

OIL PUMP (FIGURE 2-19)

GM 4.3L, GASOLINE AND LPG

2-56 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

OIL PUMP
GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

1539198 Engine Assy-Gas (2006 Series) ......................................................................... 1
b 1646673 Engine Assy-Gas (2007 Series) ......................................................................... 1
d 1649504 Engine Assy-Gas (2008 Series) ......................................................................... 1
1694587 Engine Assy-Gas (2009 Series) ......................................................................... 1
4004339 Engine Assy -Gas (2010 Series) ........................................................................ 1
1591677 Engine Assy-LPG (2006 Series) ......................................................................... 1
a 1646674 Engine Assy-LPG (2007 Series) ......................................................................... 1
c 1649334 Engine Assy-LPG (2008 Series) ......................................................................... 1
1694586 Engine Assy-LPG (2009 Series) ......................................................................... 1
4004338 Engine Assy -LPG (2010 Series) ........................................................................ 1
4019146 Engine Assy (LPG)(2010) (Heavy Duty, Optional) ............................................. 1
1386176 Engine Oil Pump ........................................................................................... 1
4020186 Engine Assy (Gas) (2011 Series) ..................................................................... 1
4020187 Engine Assy (LPG) (2011 Series) ....................................................................... 1
1 1374319 Cover ......................................................................................................... 1
2 1338223 Stop ....................................................................................................... 1
3 268573 Regulator Valve .................................................................................... 1
4 1374320 Spring ................................................................................................... 1
5 1330453 Pin ......................................................................................................... 1
6 1333541 Kit-Screw ................................................................................................... 2
7 388306 Bolt ................................................................................................................ 1
8 1386177 Screen ........................................................................................................... 1
9 1450941 Pin .................................................................................................................. 2
10 263795 Retainer ......................................................................................................... 1
11 263794 Shaft .............................................................................................................. 1

FOOTNOTES:
a → S/N G004V02853E c S/N G004V02854E →
b → S/N G004V03165E d S/N G004V03166E →

©2011 HYSTER COMPANY See Service Manual 2-57

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NOTES

2-58 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

3 FUEL SYSTEM
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 3
FUEL SYSTEM

DESCRIPTION PAGE

AIR CLEANER
GM 4.3L - GASOLINE AND LPG (→ S/N G004V03075E) ......................................................................... 3-2
GM 4.3L - GASOLINE AND LPG (S/N G004V03076E →) ......................................................................... 3-4
AIR FILTER ..................................................................................................................................................... 3-7
FUEL SYSTEM
GM 4.3L, GASOLINE .................................................................................................................................. 3-8
GM 4.3L, LPG ............................................................................................................................................. 3-12
LPG TANK BRACKET
SWING OUT (→ S/N G004V03216F (NON BCS)) (→ S/N G004V03117E (BCS)) .................................. 3-22
SWING OUT (S/N G004V03217F → (NON BCS)) (S/N G004V03118E → (BCS)) .................................. 3-24
SWING OUT/ DROP DOWN (→ S/N G004V03038E (NON BCS)) (→ S/N G004V03035E (BCS)) ......... 3-28
SWING OUT/DROP DOWN (S/N G004V03039E → (NON BCS)) (S/N G004V03036E → (BCS)) .......... 3-32
MONOTROL PEDAL ASSEMBLY ................................................................................................................... 3-38
PRE-CLEANER AND MOUNT ........................................................................................................................ 3-6
REGULATOR
LPG ............................................................................................................................................................. 3-20
THROTTLE BODY ASSEMBLY
GM 4.3L LPG (S/N G004V04608H → INC. 04572) ................................................................................... 3-18
GM 4.3L, LPG (→ S/N G004V04607H EXC. 04572) ................................................................................. 3-16
THROTTLE BODY ASSEMBLY AND FUEL RAIL
GM 4.3L, GASOLINE .................................................................................................................................. 3-10
THROTTLE PEDAL AND ATTACHING PARTS ............................................................................................. 3-36

©2011 HYSTER COMPANY See Service Manual 3-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AIR CLEANER (FIGURE 3-1)

GM 4.3L — GASOLINE AND LPG (→ S/N G004V03075E)

3-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AIR CLEANER
GM 4.3L – GASOLINE AND LPG (→ S/N G004V03075E)

ITEM PART NO. DESCRIPTION QTY

1 2070531 Air Filter (FFigure 3-4)....................................................................................... 1
2 1502009 Hose Clamp ........................................................................................................ 2
3 1567475 Hose ................................................................................................................... 1
4 112989 Hose Clamp ........................................................................................................ 3
5 2098442 Hose (Clean Air) ................................................................................................. 1
6 115696 Hose Clamp ........................................................................................................ 3
7 379407 Fitting .................................................................................................................. 1
8 1581438 Elbow .................................................................................................................. 1
9 1502079 Grommet ............................................................................................................. 1
10 1581439 Retainer .............................................................................................................. 1
11 2077239 Hose (Dirty Air) ................................................................................................... 1
12 1510113 Capscrew ............................................................................................................ 3
13 1530243 Insert ................................................................................................................... 3
14 1527879 Capscrew ............................................................................................................ 2
15 1618395 Bracket (Air Cleaner) .......................................................................................... 1
16 2067476 Grill ..................................................................................................................... 1
17 2098443 Hose (Clean Air) ................................................................................................. 1
18 1661665 Coupler (PCV) .................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 3-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AIR CLEANER (FIGURE 3-2)

GM 4.3L — GASOLINE AND LPG (S/N G004V03076E →)

3-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AIR CLEANER
GM 4.3L – GASOLINE AND LPG (S/N G004V03076E →)

ITEM PART NO. DESCRIPTION QTY

1 2070531 Air Filter (FFigure 3-4)....................................................................................... 1
2 1502009 Hose Clamp ........................................................................................................ 2
3 1567475 Hose ................................................................................................................... 1
4 112989 Hose Clamp ........................................................................................................ 3
5 2098442 Hose (Clean Air) ................................................................................................. 1
6 115696 Hose Clamp ........................................................................................................ 3
7 379407 Fitting .................................................................................................................. 1
8 1581438 Elbow .................................................................................................................. 1
9 1502079 Grommet ............................................................................................................. 1
10 1581439 Retainer .............................................................................................................. 1
11 2077239 Hose (Dirty Air) ................................................................................................... 1
12 1510113 Capscrew ............................................................................................................ 3
13 1530243 Insert ................................................................................................................... 3
14 1527879 Capscrew ............................................................................................................ 2
15 1666746 Bracket (Air Cleaner) .......................................................................................... 1
16 2067476 Grill ..................................................................................................................... 1
17 2098443 Hose (Clean Air) ................................................................................................. 1
18 1661665 Coupler (PCV) .................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 3-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

PRE-CLEANER AND MOUNT (FIGURE 3-3)

ITEM PART NO. DESCRIPTION QTY

1 1501888 Pre-Cleaner ........................................................................................................ 1
2 b 1565201 Air Duct ............................................................................................................... 1
2 c 1677793 Air Duct ............................................................................................................... 1
3 2071261 Capscrew ........................................................................................................... 2
4 1506738 Washer ............................................................................................................... 2
5 1531558 Insert .................................................................................................................. 2
ac 1677833 Screw (Pre-Cleaner Mounting) ........................................................................... 3

FOOTNOTES:
a Not Illustrated c S/N G004V04091F →
b → S/N G004V04090F

3-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AIR FILTER (FIGURE 3-4)

ITEM PART NO. DESCRIPTION QTY

2070531 Air Filter .............................................................................................................. 1
1 374923 Valve .............................................................................................................. 1
2 1620145 Inner Liner Assy (Gasket) ............................................................................... 1
3 1620142 Filter Element ................................................................................................. 1
4 a 1620144 Cover .............................................................................................................. 1
4 b 1688547 Cover .............................................................................................................. 1
5 141331 Cap ................................................................................................................. 1

FOOTNOTES:
a → S/N G004V03371F b S/N G004V03372F →

©2011 HYSTER COMPANY See Service Manual 3-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FUEL SYSTEM (FIGURE 3-5)

GM 4.3L, GASOLINE

3-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FUEL SYSTEM
GM 4.3L, GASOLINE

ITEM PART NO. DESCRIPTION QTY

1 166857 Clamp ................................................................................................................. 10
2 2066154 Hose ................................................................................................................... 1
3 1480237 Nut ...................................................................................................................... 1
4 1591480 Tube ................................................................................................................... 1
5 1543900 Hose ................................................................................................................... 1
6 1527881 Capscrew ........................................................................................................... 2
7 353000 O-Ring ................................................................................................................ 2
8 1551723 Fuel Sender ....................................................................................................... 1
8 1511727 Wire Harness ................................................................................................ 1
9 1568998 Fitting ............................................................................................................ 1
10 43883 Drain Valve (Shut-Off) .................................................................................. 1
11 12856 Fitting ............................................................................................................ 1
12 17353 Fitting ............................................................................................................ 1
13 1551665 Cover ............................................................................................................. 1
14 1501811 Fuel Sender ................................................................................................... 1
15 1528893 Quad Ring ..................................................................................................... 1
16 2058000 Adhesive ......................................................................................................... AR
17 1371149 Connector ..................................................................................................... 1
18 2066137 Hose ................................................................................................................... 2
19 1591481 Tube ................................................................................................................... 1
20 178794 Clamp ................................................................................................................. 1
21 1527879 Capscrew ........................................................................................................... 1
22 2076154 Hose ................................................................................................................... 1
23 119236 Clamp ................................................................................................................. 1
24 1553541 Fuel Filter ........................................................................................................... 1
25 1529366 Capscrew ........................................................................................................... 2
26 1564392 Pipe (Fill) ............................................................................................................ 1
27 1528314 Seal ..................................................................................................................... 1
28 2021683 Gasket ............................................................................................................ 1
29 2021679 Fuel Cap ............................................................................................................. 1
29 1579677 Fuel Cap (GS) .................................................................................................... 1
30 2021685 Gasket (GS) ....................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 3-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

THROTTLE BODY ASSEMBLY AND FUEL RAIL (FIGURE 3-6)

GM 4.3L, GASOLINE

3-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

THROTTLE BODY ASSEMBLY AND FUEL RAIL

GM 4.3L, GASOLINE

ITEM PART NO. DESCRIPTION QTY

1 1540643 Capscrew ........................................................................................................... 4
2 1557551 Gasket (Throttle Body) ..................................................................................... 1
3 1557547 Throttle Body .................................................................................................... 1
4 a 1655360 Fuel Rail .............................................................................................................. 1
4 b 1677787 Tube Assy .......................................................................................................... 1
4 1559563 Injector .......................................................................................................... 6
4 1677429 Retainer ......................................................................................................... 6
4 1559557 Clip ................................................................................................................. 1
4 1689940 Clip (Alternate Part) ...................................................................................... 1
4 1559561 Regulator ....................................................................................................... 1
4 a 1677432 Fuel Rail ......................................................................................................... 1
4 b 1686965 Fuel Rail ........................................................................................................ 1
4 1686966 Pressure Valve .............................................................................................. 1
5 2066137 Hose ................................................................................................................... 1

FOOTNOTES:
a → S/N G004V03501F b S/N G004V03502F →

©2011 HYSTER COMPANY See Service Manual 3-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FUEL SYSTEM (FIGURE 3-7)

GM 4.3L, LPG

3-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FUEL SYSTEM
GM 4.3L, LPG

ITEM PART NO. DESCRIPTION QTY

1 j 1557609 LPG Tank Bracket (Swing Out Steel) (FFigure 3-11)........................................ 1
1 p 1664027 LPG Tank Bracket (Swing Out Steel) (FFigure 3-11)........................................ 1
1 h 1557608 LPG Tank Bracket (Drop Down Steel) (FFigure 3-13)....................................... 1
1 n 1664029 LPG Tank Bracket (Drop Down Steel) (FFigure 3-13)....................................... 1
1 ai 1652185 LPG Tank Bracket (Swing Out Steel with BCS) (FFigure 3-11)........................ 1
1 ao 1664031 LPG Tank Bracket (Swing Out Steel with BCS) (FFigure 3-11)........................ 1
1 ag 1652186 LPG Tank Bracket (Drop Down Steel with BCS) (FFigure 3-13)....................... 1
1 am 1664033 LPG Tank Bracket (Drop Down Steel with BCS) (FFigure 3-13)....................... 1
2 2076168 Hose Assy ........................................................................................................... 1
3 97999 Fitting .................................................................................................................. 1
4 2071517 Sleeve ................................................................................................................. 1
5 g 1564061 Bracket (Swing Out) ............................................................................................ 1
6 ghj 1586013 Capscrew ........................................................................................................... 4
6 mnp 1586013 Capscrew ........................................................................................................... 6
7 16863 Fitting .................................................................................................................. 1
8 2070675 Hose Assy ........................................................................................................... 1
8 b 2070677 Hose Assy ........................................................................................................... 1
9 d 1568749 Tube .................................................................................................................... 1
9 c 2110915 Tube Assy ........................................................................................................... 1
10 d 14372 Fitting .................................................................................................................. 1
10 c 17314 Fitting (Not Shown) ............................................................................................. 1
11 k 2070100 Fuel Filter (LPG) ................................................................................................. 1
11 q 2105803 Fuel Filter (LPG) ................................................................................................. 1
11 k 1581302 Kit-Filter Element ............................................................................................ 1
11 q 1689544 Kit-Filter Element ............................................................................................ 1
11 e. . . . . O-Ring ....................................................................................................... 1
11 e. . . . . Filter Element ........................................................................................... 1
11 e. . . . . O-Ring ....................................................................................................... 1
11 e. . . . . Seal ............................................................................................................ 1
12 14358 Fitting .................................................................................................................. 1
13 d 16151 Fitting .................................................................................................................. 1
13 c 14349 Fitting (Pipe Plug) (Not Shown) .......................................................................... 1
14 1529366 Capscrew ........................................................................................................... 1
15 296152 Capscrew ............................................................................................................ 2
16 130845 Clamp ................................................................................................................. 4
17 f 2071012 LPG Converter /Regulator (FFigure 3-10)......................................................... 1
17 l 4602050 LPG Converter (FFigure 3-10)........................................................................... 1
18 366473 Clamp ................................................................................................................. 2
19 1527881 Capscrew ........................................................................................................... 2
20 1530243 Insert .................................................................................................................. 2
21 377211 Hose ................................................................................................................... 1
22 1542439 Clamp (Swivel) .................................................................................................... 3
23 1542436 Clamp ................................................................................................................. 2
24 2071008 Radiator Hose (Coolant) ..................................................................................... 2
25 1543842 Clamp ................................................................................................................. 1
26 1502061 Clamp ................................................................................................................. 1
27 1502059 Clamp ................................................................................................................. 1
28 2071011 Hose ................................................................................................................... 1
28 1698684 Kit-O-Ring ....................................................................................................... 1
29 1572583 Bracket ................................................................................................................ 1
©2011 HYSTER COMPANY See Service Manual 3-13
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FUEL SYSTEM
GM 4.3L, LPG

ITEM PART NO. DESCRIPTION QTY

30 2072298 Hose Assy ........................................................................................................... 1
31 16134 Fitting .................................................................................................................. 1
32 246108 Sealant ............................................................................................................... AR
33 1501970 Pressure Switch (Low Fuel) ................................................................................ 1
ce 1662253 Sensor (Vapor) ................................................................................................... 1

FOOTNOTES:
a Box Car Special j → S/N G004V03216F
b Box Car Special and Paper Roll Special k → S/N G004V03845F
c For use with premium low fuel sensor. l 10/2009 →
d For use without premium low fuel sensor. m S/N G004V03036E →
e Not Illustrated n S/N G004V03039E →
f → 10/2009 o S/N G004V03118E →
g → S/N G004V03035E p S/N G004V03217F →
h → S/N G004V03038E q S/N G004V03846F →
i → S/N G004V03117E

3-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 3-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

THROTTLE BODY ASSEMBLY (FIGURE 3-8)

GM 4.3L, LPG (→ S/N G004V04607H EXC. 04572)

3-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

THROTTLE BODY ASSEMBLY

GM 4.3L, LPG (→ S/N G004V04607H EXC. 04572)

ITEM PART NO. DESCRIPTION QTY

1 1557547 Throttle Body .................................................................................................... 1
2 1540643 Capscrew ........................................................................................................... 4
3 1557566 Hose Clamp ........................................................................................................ 12
4 1557551 Gasket (Throttle Body) ..................................................................................... 1
5 1527876 Capscrew ........................................................................................................... 4
6 125347 Fitting .................................................................................................................. 2
7 1632297 Fuel Rail .............................................................................................................. 1
7 1632298 Fuel Rail .............................................................................................................. 1
7 1632299 Fuel Rail ......................................................................................................... 1
8 a 1632300 Sensor (Fuel Pressure) .................................................................................. 1
9 1557560 Injector (LPG) ..................................................................................................... 6
10 1632301 Hose ................................................................................................................... 6
11 1632302 Adapter ............................................................................................................... 6
12 1632303 Bracket ................................................................................................................ 2
13 1632304 Tube Assy ........................................................................................................... 1
14 1632305 Tube Assy ........................................................................................................... 1
15 1557565 O-Ring ................................................................................................................ 6
b 1632307 Bracket ................................................................................................................ 2

FOOTNOTES:
a Left Rail Only b Not Illustrated

©2011 HYSTER COMPANY See Service Manual 3-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

THROTTLE BODY ASSEMBLY (FIGURE 3-9)

GM 4.3L LPG (S/N G004V04608H → INC. 04572)

3-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

THROTTLE BODY ASSEMBLY

GM 4.3L LPG (S/N G004V04608H → INC. 04572)

ITEM PART NO. DESCRIPTION QTY

1 1557547 Throttle Body ...................................................................................................... 1
2 1557551 Gasket (Throttle Body) ........................................................................................ 1
3 1540643 Capscrew ............................................................................................................ 4
4 1632305 Tube Assy ........................................................................................................... 1
5 1632304 Tube Assy ........................................................................................................... 1
6 4013329 Bracket ................................................................................................................ 2
7 4013328 Fuel Rail (LH) ...................................................................................................... 1
8 1527876 Capscrew ............................................................................................................ 8
9 4013327 Fuel Rail (RH) ..................................................................................................... 1
10 1632300 Sensor (Fuel Pressure) ....................................................................................... 1
11 4013301 Injector ................................................................................................................ 6
12 4013302 O-Ring ................................................................................................................ 6
13 4013303 O-Ring ................................................................................................................ 6
14 4013299 O-Ring ................................................................................................................ 6
15 4013304 Adapter ............................................................................................................... 6
15 1557565 O-Ring ............................................................................................................ 6
15 1632306 Lubricant ......................................................................................................... AR
16 15347 Fitting .................................................................................................................. 1
246108 Sealant ........................................................................................................... AR

©2011 HYSTER COMPANY See Service Manual 3-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

REGULATOR (FIGURE 3-10)

LPG

3-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

REGULATOR
LPG

ITEM PART NO. DESCRIPTION QTY

a 2071012 LPG Converter /Regulator .................................................................................. 1
b 4602050 LPG Converter .................................................................................................... 1
1 1581762 Fitting (Inlet Fitting With O-Ring) .................................................................... 1
2 1581763 Fitting (Outlet Fitting With O-Ring) ................................................................. 1
3 1581764 Drain Plug (With O-Ring) ................................................................................ 1
4 1585751 Kit-Screw (Includes 5 Connector Screws) ...................................................... 1
5 1585748 Kit-O-Ring (Includes 2 Coolant Fitting O-Rings) ............................................ 1
6 1585747 LPG Lock-Off .................................................................................................. 1
7 1581761 Kit-Filter .......................................................................................................... 1
7 ..... O-Ring ........................................................................................................ 1
7 ..... Plastic Cap ................................................................................................. 1
7 ..... Foam Filter ................................................................................................. 1
7 ..... Paper Filter ................................................................................................. 1
7 ..... Rubber Washer .......................................................................................... 1
7 ..... Screen ........................................................................................................ 1
1692176 Kit-Repair LPG Converter .............................................................................. 1
..... Diaphragm .................................................................................................. 1
..... Barrier, Lower ............................................................................................. 1
..... Barrier, Upper ............................................................................................. 1
..... Rubber Seal, High Pressure ...................................................................... 1
..... Support (For Rubber Seal) ......................................................................... 1
..... Pivot Pin ..................................................................................................... 1
..... Screw (For Pivot Pin) ................................................................................. 1
..... Washer ....................................................................................................... 1
..... Washer, Anti-Friction .................................................................................. 1
4600755 Fitting ......................................................................................................... 1

FOOTNOTES:
a → 10/2009 b 10/2009 →

©2011 HYSTER COMPANY See Service Manual 3-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

LPG TANK BRACKET (FIGURE 3-11)

SWING OUT (→ S/N G004V03216F (NON BCS)) (→ S/N G004V03117E (BCS))

3-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

LPG TANK BRACKET

SWING OUT (→ S/N G004V03216F (NON BCS)) (→ S/N G004V03117E (BCS))

ITEM PART NO. DESCRIPTION QTY

1557609 LPG Tank Bracket .............................................................................................. 1
1652185 LPG Tank Bracket (BCSl) ................................................................................... 1
1 1534649 Pin (Striker) .................................................................................................... 1
2 1581556 Washer ........................................................................................................... 2
3 1581885 Capscrew ....................................................................................................... 2
4 1581733 Capscrew ....................................................................................................... 2
5 1613749 Strap ............................................................................................................... 1
6 1613755 Latch ............................................................................................................... 1
7 1613763 Nut (Adjusting) ........................................................................................... 1
8 1534677 Pin .................................................................................................................. 1
9 1581739 Nut .................................................................................................................. 2
10 1581740 Capscrew ....................................................................................................... 1
11 1585835 Capscrew ....................................................................................................... 2
12 1581583 Capscrew ....................................................................................................... 1
13 1581898 Washer ........................................................................................................... 1
14 1525459 Pin (Alignment) ............................................................................................... 1
15 101809 Relief Valve .................................................................................................... 1
16 1581559 Washer ........................................................................................................... 1
17 1528899 Spring ............................................................................................................. 1
18 182118 Retaining Ring ................................................................................................ 1
19 34507 Snap Ring ....................................................................................................... 1
20 1568839 Washer (Pivot) ................................................................................................ 1
21 184451 Ball Bearing .................................................................................................... 2
22 1568853 Thrust Washer ................................................................................................ 1
23 1528903 Spring ............................................................................................................. 1
24 1534672 Ring ................................................................................................................ 1
25 1534671 Pin .................................................................................................................. 1
26 1582474 Support ........................................................................................................... 1
27 1568844 Base Weldment (Shown) ................................................................................ 1
27 1652033 Base (BCS, Not Illustrated) ............................................................................ 1
28 1581579 Capscrew ....................................................................................................... 1
29 1525451 Fitting .............................................................................................................. 1
30 1398099 Plug ................................................................................................................ 4
31 1534675 Fitting (Bulkhead) ........................................................................................... 1
32 1534679 Block (Anti-Rattle) .......................................................................................... 1
33 1517405 Latch ............................................................................................................... 1
34 1534674 Plate ............................................................................................................... 1
35 1581899 Capscrew ....................................................................................................... 4
a 1687377 Activator (Alternate Part) ................................................................................ 1

FOOTNOTES:
a Not Illustrated

©2011 HYSTER COMPANY See Service Manual 3-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

LPG TANK BRACKET (FIGURE 3-12)

SWING OUT (S/N G004V03217F → (NON BCS)) (S/N G004V03118E → (BCS))

3-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

LPG TANK BRACKET

SWING OUT (S/N G004V03217F → (NON BCS)) (S/N G004V03118E → (BCS))

ITEM PART NO. DESCRIPTION QTY

1664027 LPG Tank Bracket (Assembly) ........................................................................... 1
1664031 LPG Tank Bracket (Assembly) (BCSl) ................................................................ 1
1 1664009 LPG Tank Bracket (Support) .......................................................................... 1
2 1398099 Plug ................................................................................................................ 4
3 1581898 Washer ........................................................................................................... 1
4 1581583 Capscrew ....................................................................................................... 1
5 101809 Relief Valve .................................................................................................... 1
6 1534675 Fitting .............................................................................................................. 1
7 1656325 Latch ............................................................................................................... 1
8 1649565 Plate ............................................................................................................... 1
9 296156 Capscrew ....................................................................................................... 4
10 1656901 Base Plate (Standard) (Shown) ...................................................................... 1
10 1664016 Base Plate (BCS) (Not Illustrated) .................................................................. 1
11 1525451 Fitting .............................................................................................................. 1
12 1581579 Capscrew ....................................................................................................... 1
13 1568853 Thrust Washer ................................................................................................ 1
14 184451 Ball Bearing .................................................................................................... 2
15 1568839 Washer (Pivot) ................................................................................................ 1
16 34507 Snap Ring ....................................................................................................... 1
17 1534672 Ring ................................................................................................................ 1
18 1615956 Pin .................................................................................................................. 1
19 1528903 Spring ............................................................................................................. 1
20 1581559 Washer ........................................................................................................... 1
21 1528899 Spring ............................................................................................................. 1
22 182118 Retaining Ring ................................................................................................ 1
23 1684323 Pin (Alignment) ............................................................................................... 1
24 1581739 Nut .................................................................................................................. 2
25 1581733 Capscrew ....................................................................................................... 2
26 1613749 Strap ............................................................................................................... 1
27 1613755 Latch ............................................................................................................... 1
28 1682755 Striker ................................................................................................................. 1
29 1688803 Shim .................................................................................................................... 1
30 1586013 Capscrew ............................................................................................................ 6
31 1656903 Bracket (BCS) ..................................................................................................... 1
32 b 2076168 Hose Assy ........................................................................................................... 1
32 c 2111871
4607258
4609648 Hose Assy ........................................................................................................... 1
33 b 16134 Fitting .................................................................................................................. 1
33 c 16134 Fitting .................................................................................................................. 2
34 b 16863 Fitting .................................................................................................................. 1
34 c 14358 Fitting .................................................................................................................. 1
35 2071517 Sleeve ................................................................................................................. 1
36 97999 Fitting .................................................................................................................. 1
37 2072298 Hose Assy ........................................................................................................... 1
38 1590389 Bumper ............................................................................................................... 1
a 1687377 Activator (Alternate Part) .................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 3-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a Not Illustrated
b → S/N G004V04374G
c S/N G004V04375G →

3-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 3-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

LPG TANK BRACKET (FIGURE 3-13)

SWING OUT/ DROP DOWN (→ S/N G004V03038E (NON BCS)) (→ S/N G004V03035E (BCS))

3-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

LPG TANK BRACKET

SWING OUT/ DROP DOWN (→ S/N G004V03038E (NON BCS)) (→ S/N G004V03035E (BCS))

ITEM PART NO. DESCRIPTION QTY

1557608 LPG Tank Bracket .............................................................................................. 1
1652186 LPG Tank Bracket (BCS) .................................................................................... 1
1 1615671 Pivot (Intermediate) ........................................................................................ 1
2 34507 Snap Ring ....................................................................................................... 1
3 1568839 Washer (Pivot) ................................................................................................ 1
4 184451 Ball Bearing .................................................................................................... 2
5 1568853 Thrust Washer (Thrust) .................................................................................. 1
6 302363 Dowel ............................................................................................................. 1
7 1581887 Shaft ............................................................................................................... 1
8 1581888 Bushing .......................................................................................................... 2
9 1581739 Nut .................................................................................................................. 4
10 1584091 LPG Tank Bracket Support ............................................................................ 1
11 1517405 Latch ............................................................................................................... 1
12 1581733 Capscrew ....................................................................................................... 2
13 1613749 Strap ............................................................................................................... 1
14 1613755 Latch ............................................................................................................... 1
15 1613763 Nut (Adjustment) ........................................................................................ 1
16 1581885 Capscrew ....................................................................................................... 2
17 1534649 Pin (Striker) .................................................................................................... 1
18 1581556 Washer ........................................................................................................... 2
19 1534674 Plate ............................................................................................................... 1
20 1581899 Capscrew ....................................................................................................... 4
21 1581740 Capscrew ....................................................................................................... 1
22 1398099 Plug ................................................................................................................ 4
23 1534677 Pin .................................................................................................................. 1
24 1581898 Washer ........................................................................................................... 1
25 1585835 Capscrew ....................................................................................................... 2
26 1581583 Capscrew ....................................................................................................... 1
27 1534679 Block (Anti-Rattle) .......................................................................................... 1
28 101809 Relief Valve .................................................................................................... 1
29 264134 Loctite ............................................................................................................. AR
30 1534675 Fitting .............................................................................................................. 1
31 1525459 Pin (Alignment) ............................................................................................... 1
32 1581559 Washer ........................................................................................................... 1
33 1528899 Spring ............................................................................................................. 1
34 182118 Retaining Ring ................................................................................................ 1
35 1525451 Fitting .............................................................................................................. 1
36 1581579 Capscrew ....................................................................................................... 1
37 1534671 Pin .................................................................................................................. 1
38 1534672 Ring ................................................................................................................ 1
39 1528903 Spring ............................................................................................................. 1
40 1568844 Base Weldment (Shown) ................................................................................ 1
40 1652033 Base Weldment (BCS, Not Illustrated ............................................................ 1
41 1525478 Pin .................................................................................................................. 1
42 1581848 Nut .................................................................................................................. 1
43 246108 Sealant ........................................................................................................... AR
43 1687376 Sealant (Alternate Part) .................................................................................. AR
43 1687377 Activator (Alternate Part) ................................................................................ AR
44 1586022 Capscrew ....................................................................................................... 1
45 1581557 Washer ........................................................................................................... 2

©2011 HYSTER COMPANY See Service Manual 3-29

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

LPG TANK BRACKET

SWING OUT/ DROP DOWN (→ S/N G004V03038E (NON BCS)) (→ S/N G004V03035E (BCS))

ITEM PART NO. DESCRIPTION QTY

46 1525442 E-Ring ............................................................................................................ 2
47 1402414 Gas Spring ..................................................................................................... 1

3-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 3-31

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

LPG TANK BRACKET (FIGURE 3-14)

SWING OUT/DROP DOWN (S/N G004V03039E → (NON BCS)) (S/N G004V03036E → (BCS))

3-32 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

LPG TANK BRACKET

SWING OUT/DROP DOWN (S/N G004V03039E → (NON BCS)) (S/N G004V03036E → (BCS))

ITEM PART NO. DESCRIPTION QTY

1664029 LPG Tank Bracket (Assembly) ........................................................................... 1
1664033 LPG Tank Bracket (BCS) .................................................................................... 1
1 1664014 LPG Tank Bracket Support ............................................................................ 1
2 1398099 Plug ................................................................................................................ 4
3 1581898 Washer ........................................................................................................... 1
4 1581583 Capscrew ....................................................................................................... 1
5 1656325 Latch ............................................................................................................... 1
6 1649565 Plate ............................................................................................................... 1
7 296156 Capscrew ....................................................................................................... 4
8 1534675 Fitting .............................................................................................................. 1
9 101809 Relief Valve .................................................................................................... 1
10 1656901 Base Plate (Shown) ........................................................................................ 1
10 1664016 Base Plate (BCS, Not Illustrated) ....................................................................... 1
11 1525451 Fitting .............................................................................................................. 1
12 1581579 Capscrew ....................................................................................................... 1
13 182118 Retaining Ring ................................................................................................ 1
14 1581559 Washer ........................................................................................................... 1
15 1528899 Spring ............................................................................................................. 1
16 1568853 Thrust Washer ................................................................................................ 1
17 184451 Ball Bearing .................................................................................................... 2
18 1568839 Washer (Pivot) ................................................................................................ 1
19 34507 Snap Ring ....................................................................................................... 1
20 1525478 Pin .................................................................................................................. 1
21 1581888 Bushing .......................................................................................................... 2
22 1402414 Gas Spring ..................................................................................................... 1
23 1581557 Washer ........................................................................................................... 2
24 1525442 E-Ring ............................................................................................................ 2
25 302363 Dowel ............................................................................................................. 1
25 302468 Roll Pin ........................................................................................................... 1
26 1581887 Shaft ............................................................................................................... 1
27 1615956 Pin .................................................................................................................. 1
28 1534672 Ring ................................................................................................................ 1
29 1528903 Spring ............................................................................................................. 1
30 1615671 Pivot ............................................................................................................... 1
31 1581848 Nut .................................................................................................................. 1
32 1586022 Capscrew ....................................................................................................... 1
33 1525459 Pin (Alignment) ............................................................................................... 1
34 1581739 Nut .................................................................................................................. 2
35 1581733 Capscrew ....................................................................................................... 2
36 1613749 Strap ............................................................................................................... 1
37 1613755 Latch ............................................................................................................... 1
38 1586022 Capscrew ............................................................................................................ 1
39 1664055 Pin (Striker) ......................................................................................................... 1
39 1682758 Striker (Alternate Part) ........................................................................................ 1
40 1655330 Bracket (BCS) ..................................................................................................... 1
41 b 16134 Fitting .................................................................................................................. 1
41 c 16134 Fitting .................................................................................................................. 2
42 b 2076168 Hose Assy ........................................................................................................... 1
42 c 2111871
4607258 Hose Assy ........................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 3-33

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

LPG TANK BRACKET

SWING OUT/DROP DOWN (S/N G004V03039E → (NON BCS)) (S/N G004V03036E → (BCS))

ITEM PART NO. DESCRIPTION QTY

4609648
43 b 16863 Fitting .................................................................................................................. 1
43 c 14358 Fitting .................................................................................................................. 1
44 2071517 Sleeve ................................................................................................................. 1
45 97999 Fitting .................................................................................................................. 1
46 2072298 Hose Assy ........................................................................................................... 1
a 1687377 Activator (Alternate Part) .................................................................................... 1

FOOTNOTES:
a Not Illustrated c S/N G004V04375G →
b → S/N G004V04374G

3-34 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 3-35

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

THROTTLE PEDAL AND ATTACHING PARTS (FIGURE 3-15)

3-36 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

THROTTLE PEDAL AND ATTACHING PARTS

ITEM PART NO. DESCRIPTION QTY
1 c 1538488 Throttle Plate ...................................................................................................... 1
1 d 1654411 Throttle Plate ...................................................................................................... 1
1 1524267 Bushing .......................................................................................................... 1
2 c 1521005 Shaft ................................................................................................................... 1
2 d 1654754 Shaft ................................................................................................................... 1
3 1530971 E-Ring ................................................................................................................. 1
4 1527879 Capscrew ............................................................................................................ 3
5 1530311 Screw (Stop) ....................................................................................................... 1
6 329069 Nut ...................................................................................................................... 1
7 1608412 Monotrol Pedal Assembly (FFigure 3-16).......................................................... 1
8 a 302437 Roll Pin ............................................................................................................... 1
8 b 302443 Roll Pin ............................................................................................................... 1
9 2071181 Pedal (Standard) ................................................................................................. 1
10 1564752 Capscrew ............................................................................................................ 2
11 2063842 Sensor (Half Throttle Position) ............................................................................ 1
12 296378 Washer ............................................................................................................... 2
13 1582301 Spring (Inner) ...................................................................................................... 1
14 1582300 Spring (Outer) ..................................................................................................... 1

FOOTNOTES:
a For Use With Monotrol Pedal Only c → S/N G004E02105E
b For Use With Standard Pedal Only d S/N G004V02106E →

©2011 HYSTER COMPANY See Service Manual 3-37

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MONOTROL PEDAL ASSEMBLY (FIGURE 3-16)

3-38 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MONOTROL PEDAL ASSEMBLY

ITEM PART NO. DESCRIPTION QTY
1608412 Monotrol Pedal Assembly ................................................................................ 1
1 2074702 Pedal .............................................................................................................. 1
2 220428 Screw ............................................................................................................. 4
3 2072782 Wire Harness ................................................................................................ 1
4 1330416 Connector ................................................................................................. 1
5 1489655 Connector (4 Way) ................................................................................... 1
6 1531312 Terminal .................................................................................................... 4
7 ..... Switch ........................................................................................................ 1
8 ..... Switch ........................................................................................................ 1
9 1564526 Clip (Key Hole) .............................................................................................. 1
10 362036 Washer .......................................................................................................... 2
11 15931 Lockwasher ................................................................................................... 4
12 1340470 Pad ................................................................................................................. 1
13 325699 Spring ............................................................................................................ 2
14 16708 Screw ............................................................................................................. 4
15 1500912 Clip ................................................................................................................. 1
16 16865 Nut ................................................................................................................. 4
17 53162 Lockwasher ................................................................................................... 4

©2011 HYSTER COMPANY See Service Manual 3-39

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NOTES

3-40 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

4 ELECTRICAL SYSTEM
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 4
ELECTRICAL SYSTEM

DESCRIPTION PAGE

DISTRIBUTOR ASSEMBLY ............................................................................................................................ 4-56

ELECTRICAL SYSTEM
COWL, ELECTRONIC HYDRAULIC - WITH OPERATOR PRESENCE SYSTEM .................................... 4-16
COWL, MANUAL HYDRAULIC - WITH OPERATOR PRESENCE SYSTEM ............................................. 4-18
COWL, WITHOUT OPERATOR PRESENCE SYSTEM ............................................................................. 4-14
ENGINE, GM 4.3L, GASOLINE AND LPG .................................................................................................. 4-6
ENGINE, GM 4.3L, GS AND LPS ............................................................................................................... 4-10
LOAD WEIGH ............................................................................................................................................. 4-24
MAST .......................................................................................................................................................... 4-22
RIGHT HAND CHASSIS ............................................................................................................................. 4-4
TRANSMISSION ......................................................................................................................................... 4-20
ELECTRONIC CONTROL LEVERS
MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) - DATE CODE 0725 THROUGH 0743 ............... 4-34
MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) - DATE CODE 0744 ........................................... 4-42
MINI-LEVER MODULES - DATE CODE 0724 ............................................................................................ 4-30
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0725 THROUGH 0743 ............................ 4-32
MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0744 ......................................................... 4-38
IMPACT SENSOR ........................................................................................................................................... 4-60
INSTRUMENT CLUSTER ............................................................................................................................... 4-57
MINI-LEVER CONTROLS
WITH ARMREST - THREE FUNCTION (S/N G004V04680H → EXC. 04683) ......................................... 4-46
WITH ARMREST - FOUR FUNCTION (S/N G004V04680H → EXC. 04683) ........................................... 4-48
WITH ARMREST - FIVE FUNCTION (S/N G004V04680H → EXC. 04683) .............................................. 4-50
POWER DISTRIBUTION MODULE
→ S/N G004V01735D ................................................................................................................................ 4-26
S/N G004V01736D → ................................................................................................................................ 4-28
REMOTE KEY SWITCH .................................................................................................................................. 4-52
SEALED ALTERNATOR AND MOUNTING
GM 4.3L ....................................................................................................................................................... 4-53
STARTER
GM 4.3L, GS AND LPS ............................................................................................................................... 4-54
WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER - MANUAL, WITH OPERATOR PRESENCE ..................... 4-126
COWL WITH FORWARD/REVERSE LEVER - WITHOUT RETURN TO SET TILT .................................. 4-130
COWL WITH MONOTROL PEDAL - WITH RETURN TO SET TILT .......................................................... 4-134
COWL WITH MONOTROL PEDAL - WITH HYDRAULIC PUMP SOLENOID ............................................ 4-138
ELECTRONIC CONTROL VALVE - THREE FUNCTION ........................................................................... 4-142
ELECTRONIC CONTROL VALVE - FOUR FUNCTION ............................................................................. 4-144
ELECTRONIC CONTROL VALVE - FIVE FUNCTION ............................................................................... 4-146
ENGINE - GM 4.3L, GASOLINE (→ S/N G004V03165E) .......................................................................... 4-104
ENGINE - GM 4.3L, GASOLINE (S/N G004V03166E ↔ S/N G004V04601H EXC. 04572) ..................... 4-106
ENGINE - GM 4.3L, LPG (→ S/N G004V02853E) ..................................................................................... 4-114
ENGINE - GM 4.3L, LPG (S/N G004V02854E ↔ S/N G004V04601H EXC. 04572) ................................. 4-116
JOYSTICK ................................................................................................................................................... 4-148
LEFT HAND CHASSIS - GM 4.3L, GASOLINE (→ S/N G004V04601H EXC. 04572) .............................. 4-94
LEFT HAND CHASSIS - GM 4.3L GASOLINE (SERIES 2010) (S/N G004V04608H → INC. 04572) ....... 4-96
LEFT HAND CHASSIS - GM 4.3L, LPG (→ S/N G004V04607H EXC. 04572) ......................................... 4-98
LEFT HAND CHASSIS - GM 4.3L LPG (2010 SERIES)(WITH PREMIUM LOW FUEL
SENSOR) (S/N G004V04608H → INC. 04572) ......................................................................................... 4-100
©2011 HYSTER COMPANY See Service Manual 4-1
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

SECTION 4
ELECTRICAL SYSTEM

DESCRIPTION PAGE

LEFT HAND CHASSIS - GM 4.3L LPG (2010 SERIES)(WITHOUT PREMIUM LOW FUEL
SENSOR) (S/N G004V04608H → INC. 04572) ......................................................................................... 4-102
LIGHTS (→ S/N G004V01639D) ................................................................................................................ 4-154
LIGHTS (S/N G004V01640D ↔ 6/2007) .................................................................................................... 4-156
LIGHTS (6/2007 →) ................................................................................................................................... 4-158
LOW FUEL SENSOR .................................................................................................................................. 4-160
RIGHT HAND CHASSIS - GM 4.3L (→ 8/2006) ........................................................................................ 4-62
RIGHT HAND CHASSIS - GM 4.3L (8/2006 ↔ S/N G004V02853E (LPG))
(8/2006 ↔ S/N G004V03165E (GASOLINE)) ............................................................................................ 4-68
RIGHT HAND CHASSIS - GM 4.3L (S/N G004V02854E ↔ S/N G004V04328G (LPG))
(S/N G004V03166E ↔ S/N G004V04328G (GASOLINE)) ........................................................................ 4-74
RIGHT HAND CHASSIS - GM 4.3L (S/N G004V04329G ↔ PENDING PER ECN 10551437) ................. 4-80
RIGHT HAND CHASSIS - GM 4.3L (PENDING PER ECN 10551437 →) ................................................. 4-86
SEALED ALTERNATOR - GM 4.3L ............................................................................................................ 4-123
SEAT JUMPER (→ PENDING PER ECN 10551437) ................................................................................ 4-92
TRANSMISSION - SINGLE SPEED ........................................................................................................... 4-150
TRANSMISSION - DUAL SPEED ............................................................................................................... 4-152
WIRE HARNESS (ENGINE)
GM 4.3L GASOLINE (2010 SERIES) (S/N G004V04608H → INC. 04572) ............................................... 4-110
GM 4.3L LPG (2010 SERIES) (S/N G004V04608H → INC. 04572) .......................................................... 4-120
WORK, REAR DRIVE, AND BRAKE/TAIL LIGHTS ........................................................................................ 4-58

4-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM (FIGURE 4-1)

RIGHT HAND CHASSIS

4-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRICAL SYSTEM
RIGHT HAND CHASSIS

ITEM PART NO. DESCRIPTION QTY

1 1540805 Cap ..................................................................................................................... 1
2 1502543 Nut (Flange) ....................................................................................................... 3
3 c 1585529 Link (Battery Hold Down) .................................................................................... 1
3 f 1638706 Link (Battery Hold Down) .................................................................................... 1
3 l 1641368 Link (Battery Hold Down) ................................................................................. 1
4 1582464 Fastener ............................................................................................................. 6
5 1500912 Clip ..................................................................................................................... 6
6 b 1627422 Battery Tray ........................................................................................................ 1
6 l 2090661 Battery Tray ....................................................................................................... 1
7 1559928 Seal .................................................................................................................... 1
8 c 2085952 Wire Harness (Gasoline and LPG) (FFigure 4-27)............................................ 1
8 gh 2090887 Wire Harness (Gasoline and LPG) (FFigure 4-29)............................................ 1
8 ij 2097392 Wire Harness (FFigure 4-29)............................................................................. 1
8 k 2105635 Wire Harness (FFigure 4-30)............................................................................. 1
8 m 4606204 Wire Harness (FFigure 4-31)........................................................................... 1
9 1624185 Bracket ............................................................................................................... 1
10 1530243 Insert .................................................................................................................. 1
11 1480237 Nut ...................................................................................................................... 4
12 d 1527264 Horn .................................................................................................................... 1
12 n 1618978 Horn ................................................................................................................... 1
13 b 1527879 Capscrew ........................................................................................................... 3
13 l 1527880 Capscrew ........................................................................................................... 3
14 1624117 Bracket ............................................................................................................... 1
15 1593331 Connector ........................................................................................................... 1
16 1510113 Capscrew ........................................................................................................... 2
17 e 2063093 Module (FFigure 4-10)....................................................................................... 1
17 o 2090613 Module (FFigure 4-11)..................................................................................... 1
18 2065745 Link (Battery Hold Down) ................................................................................. 1
19 1534417 Capscrew ........................................................................................................... 4
20 1402883 Fuse Puller ........................................................................................................ 1
21 1529366 Capscrew ........................................................................................................... 1
22 1383331 Start Battery Wet ................................................................................................ 1
23 1617080 Bracket (Hood Switch) ..................................................................................... 1
24 1531557 Insert .................................................................................................................. 1
25 1527879 Capscrew ........................................................................................................... 1
26 296380 Washer ............................................................................................................... 1
a 4601500 Wire Harness (Seat Adapter) (FFigure 4-32).................................................... 1

FOOTNOTES:
a Not Illustrated i S/N G004V02854E ↔ S/N G004V04328G (LPG)
b → 11/2006 j S/N G004V03166E ↔ S/N G004V04328G
c → 8/2006 (Gasoline)
d → S/N G004V01582D k S/N G004V04329G ↔ PENDING PER ECN
e → S/N G004V01735D 10551437
f 8/2006 ↔ 11/2006 l 11/2006 →
g 8/2006 ↔ S/N G004V02853E (LPG) m PENDING PER ECN 10551437 →
h 8/2006 ↔ S/N G004V03165E (Gasoline) n S/N G004V01583D →
o S/N G004V01736D →

©2011 HYSTER COMPANY See Service Manual 4-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM (FIGURE 4-2)

ENGINE, GM 4.3L, GASOLINE AND LPG

4-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRICAL SYSTEM
ENGINE, GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

1 2072157 Battery Cable (Positive) ................................................................................... 1
1 1357268 Battery Cable (Red) ...................................................................................... AR
1 1474893 Clamp ............................................................................................................ 1
1 148792 Terminal ........................................................................................................ 1
1 153070 Clamp ............................................................................................................ 1
1 1536304 Boot ............................................................................................................... 1
1 1590173 Boot ............................................................................................................... 1
1 806426 E-Ring ............................................................................................................ 1
1 1590368 Terminal ........................................................................................................ 1
2 1520513 Clip ...................................................................................................................... 1
3 1618503 Bracket ................................................................................................................ 1
4 1544157 Clip ..................................................................................................................... 2
5 1480237 Nut ...................................................................................................................... 2
6 1527879 Capscrew ........................................................................................................... 6
7 1626984 Grommet ............................................................................................................. 1
8 1557546 Oxygen Sensor (With Wire Harness) .............................................................. 2
9 1632294 Bracket ............................................................................................................... 1
10 1309993 Screw ................................................................................................................. 1
11 1618500 Bracket ................................................................................................................ 1
11 1590368 Terminal ........................................................................................................ 1
12 1510113 Capscrew ........................................................................................................... 2
13 1530243 Insert .................................................................................................................. 2
14 15052 Nut ...................................................................................................................... 2
15 1640818 Bracket ............................................................................................................... 1
16 1397716 Bolt ...................................................................................................................... 2
16 1677876 Bolt (Alternate Part) .......................................................................................... 2
17 292681 Lockwasher ....................................................................................................... 1
18 1640531 Starter ................................................................................................................ 1
19 264148 Nut ...................................................................................................................... 2
20 292668 Nut ...................................................................................................................... 1
21 1502543 Nut (Flange) ....................................................................................................... 1
22 1527876 Capscrew ........................................................................................................... 1
23 1402629 Bracket ............................................................................................................... 1
24 1402816 Clip ..................................................................................................................... 2
25 ad 2077809 Wire Harness (LH Chassis) (FFigure 4-33)....................................................... 1
25 ae 4604532 Wire Harness (LH Chassis) (2010 Series) (FFigure 4-34)............................. 1
26 bd 2077810 Wire Harness (LH Chassis) (FFigure 4-35)....................................................... 1
26 bce 4604390 Wire Harness (LH Chassis) (2010 Series) (FFigure 4-36)................................ 1
26 be 4604393 Wire Harness (LH Chassis) (2010 Series) (FFigure 4-37)................................ 1
27 1502061 Clamp ................................................................................................................. 1
28 1561871 Clamp (Swivel) .................................................................................................. 1
29 1529366 Capscrew ........................................................................................................... 1
30 296380 Washer ............................................................................................................... 1
31 2072159 Battery Cable (Negative) .................................................................................. 1
31 16078 Battery Cable ................................................................................................ AR
31 148789 Terminal ........................................................................................................ 1
31 1616122 Terminal (Alternate Part) ............................................................................. 1
31 148796 Terminal ......................................................................................................... 1
31 1564044 E-Ring ............................................................................................................ 1
31 153070 Clamp ............................................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 4-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM
ENGINE, GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

31 806426 E-Ring ............................................................................................................ 1

FOOTNOTES:
a Gasoline d → S/N G004V04607H EXC. 04572
b LPG e S/N G004V04608H → INC. 04572
c With Preminum Low Fuel Sensor

4-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM (FIGURE 4-3)

ENGINE, GM 4.3L, GS AND LPS

4-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRICAL SYSTEM
ENGINE, GM 4.3L, GS AND LPS
KEY:
A: GS
B: LPS
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1517361 Locking Ring Cotter Pin .......................................................................... 1 1
2 126 Pin .............................................................................................................. 1 1
3 2071501 Battery Cable Assembly ............................................................................. 1 1
3 148792 Terminal ................................................................................................ 1 1
3 1590368 Terminal ................................................................................................ 1 1
3 204223 Boot ....................................................................................................... 1 1
3 1536304 Boot ....................................................................................................... 1 1
4 1578660 Switch ......................................................................................................... 1 1
5 15916 Lockwasher ................................................................................................ 2 2
6 15002 Nut .............................................................................................................. 2 2
7 15156 Lockwasher ................................................................................................ 2 2
8 17407 Nut .............................................................................................................. 2 2
9 1480237 Nut ............................................................................................................. 2 2
9 d 1566420 Nut (Alternate Part) .................................................................................. 2 2
9 g 1566420 Nut ............................................................................................................. 1 1
10 2094582 Wire Harness Sealed Alternator ................................................................. 1 1
11 1529257 Sensor (Air Flow Restriction) ..................................................................... 1 1
12 c 1646410 Bracket ....................................................................................................... 1 1
12 df 1648116 Bracket ....................................................................................................... 1 1
12 g 1688164 Bracket ....................................................................................................... 1 1
13 1527879 Capscrew .................................................................................................. 4 4
13 d 1527877 Capscrew (Alternate Part) ....................................................................... 2 2
13 g 1527877 Capscrew .................................................................................................. 1 1
14 2093470 Battery Cable (Positive) ............................................................................. 1 1
15 1309993 Screw ......................................................................................................... 1 1
16 1632294 Bracket ...................................................................................................... 1 1
17 264148 Nut ............................................................................................................. 2 2
18 1397716 Bolt ............................................................................................................. 2 2
19 1640818 Bracket ...................................................................................................... 1 1
20 1502061 Clamp ........................................................................................................ 1 1
21 1557546 Oxygen Sensor (With Wire Harness) ...................................................... 2 2
22 1561871 Clamp (Swivel) .......................................................................................... 1 2
23 1640531 Starter ........................................................................................................ 1 1
24 1402629 Bracket ...................................................................................................... 1 ..
25 e 2077809 Wire Harness (LH Chassis) (FFigure 4-33).............................................. 1 ..
25 e 2077810 Wire Harness (LH Chassis) (FFigure 4-35).............................................. .. 1
25 h 4604532 Wire Harness (LH Chassis) (2010 Series) (FFigure 4-34).................... 1 ..
25 bh 4604390 Wire Harness (LH Chassis) (2010 Series) (FFigure 4-36)........................ .. 1
25 h 4604393 Wire Harness (LH Chassis) (2010 Series) (FFigure 4-37)........................ .. 1
26 1527876 Capscrew .................................................................................................. 3 3
27 1514429 Nut ............................................................................................................. 1 1
28 1402816 Clip ............................................................................................................ 2 ..
29 1543698 Clamp (Swivel) .......................................................................................... 2 2

©2011 HYSTER COMPANY See Service Manual 4-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM
ENGINE, GM 4.3L, GS AND LPS
KEY:
A: GS
B: LPS
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
30 1542440 Clamp (Swivel) ........................................................................................... 3 3
31 1565382 Bracket ....................................................................................................... 1 1
31 1703868 Bracket (Alternate Part) .............................................................................. 1 1
32 1531558 Insert ......................................................................................................... 2 2
33 2083129 Cable Assy (Emergency Stop) ................................................................... 1 1
34 1562088 Clip ............................................................................................................ 1 1
35 1561759 Clamp (Swivel) ........................................................................................... 1 1
36 1529366 Capscrew .................................................................................................. 1 1
37 296380 Washer ...................................................................................................... 1 1
38 2093469 Battery Cable (Negative) ............................................................................ 1 1
a 1502543 Nut (Flange) .............................................................................................. 1 1
a 292681 Lockwasher .............................................................................................. 1 1
a 292668 Nut ............................................................................................................. 1 1

FOOTNOTES:
a Not Illustrated e → S/N G004V04607H EXC. 04572
b With Preminum Low Fuel Sensor f 11/2006 →
c → 11/2006 g 11/2008 →
d → 11/2008 h S/N G004V04608H → INC. 04572

4-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM (FIGURE 4-4)

COWL, WITHOUT OPERATOR PRESENCE SYSTEM

4-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRICAL SYSTEM
COWL, WITHOUT OPERATOR PRESENCE SYSTEM

ITEM PART NO. DESCRIPTION QTY

1 2070269 Wire Harness (With Monotrol) (FFigure 4-47)................................................... 1
1 2084829 Wire Harness (Cowl with Forward/Reverse Lever) (FFigure 4-46)................... 1
2 1600190 Bracket ................................................................................................................ 1
2 2111004 Bracket (Left Hand) (Alternate Part) ................................................................... 1
3 1531975 Bracket ................................................................................................................ 1
4 1529366 Capscrew ............................................................................................................ 2
5 1500912 Clip ...................................................................................................................... 3
6 1582465 Bracket ................................................................................................................ 3
7 1582465 Bracket ................................................................................................................ 1
8 1510115 Capscrew ............................................................................................................ 3
9 2068342 Vehicle System Manager (VSM) (8525419) ....................................................... 1
9 2068343 Vehicle System Manager (VSM) (8525420) ....................................................... 1
10 2058909 Wire Harness (Electronic Control Valve) ............................................................ 1
10 2060198 Wire Harness (Electronic Control Valve) ............................................................ 1
10 2079402 Wire Harness (Electronic Control Valve) ............................................................ 1
11 1529366 Capscrew ............................................................................................................ 4
12 2111005 Bracket (Right Hand) (Alternate Part) ................................................................. 1

©2011 HYSTER COMPANY See Service Manual 4-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM (FIGURE 4-5)

COWL, ELECTRONIC HYDRAULIC — WITH OPERATOR PRESENCE SYSTEM

4-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRICAL SYSTEM
COWL, ELECTRONIC HYDRAULIC – WITH OPERATOR PRESENCE SYSTEM

ITEM PART NO. DESCRIPTION QTY

1 d 2098011 Wire Harness (FFigure 4-47)............................................................................. 1
1 f 2098012 Wire Harness (Cowl with Forward/Reverse Lever) (FFigure 4-46)................... 1
2 1600190 Bracket ................................................................................................................ 1
2 2111004 Bracket (Left Hand) (Alternate Part) ................................................................ 1
3 1531975 Bracket ................................................................................................................ 1
4 1529366 Capscrew ........................................................................................................... 2
4 1529366 Capscrew (Alternate Parts) .............................................................................. 2
5 1500912 Clip ..................................................................................................................... 3
6 1582464 Fastener ............................................................................................................. 3
7 1582465 Bracket ............................................................................................................... 1
8 1510115 Capscrew ........................................................................................................... 3
9 e 2068342 Vehicle System Manager (VSM) ...................................................................... 1
9 c 2068343 Vehicle System Manager (VSM) ......................................................................... 1
10 a 2058909 Wire Harness (Electronic Control Valve) (FFigure 9-21)................................... 1
10 b 2060198 Wire Harness (Electronic Control Valve) (FFigure 9-19)................................... 1
11 1529366 Capscrew ........................................................................................................... 4
12 2111005 Bracket (Right Hand) (Alternate Part) ............................................................. 1

FOOTNOTES:
a Four Function d With Return to Set Tilt
b Three Function e Without Electronic Hydraulics
c With Electronic Hydraulics f Without Return to Set Tilt

©2011 HYSTER COMPANY See Service Manual 4-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM (FIGURE 4-6)

COWL, MANUAL HYDRAULIC — WITH OPERATOR PRESENCE SYSTEM

4-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRICAL SYSTEM
COWL, MANUAL HYDRAULIC – WITH OPERATOR PRESENCE SYSTEM

ITEM PART NO. DESCRIPTION QTY

1 2104701 Wire Harness (Cowl with Monotrol) (FFigure 4-48)...................................... 1
1 2104702 Wire Harness (Cowl with Forward/Reverse Lever) (FFigure 4-45)................... 1
2 1529366 Capscrew ........................................................................................................... 2
3 1600190 Bracket ................................................................................................................ 1
3 2111004 Bracket (Left Hand) (Alternate Part) ................................................................ 1
3 2111005 Bracket (Right Hand) (Alternate Part) ............................................................. 1
4 1500912 Clip (With Monotrol) ......................................................................................... 4
4 1500912 Clip (Without Forward/Reverse Lever) ........................................................... 3
4 1582464 Fastener (With Monotrol) ................................................................................. 4
4 1582464 Fastener (Without Forward/Reverse Lever) ................................................... 3
5 a 2068342 Vehicle System Manager (VSM) (8525419) ..................................................... 1
6 1582465 Bracket ............................................................................................................... 1
7 1510115 Capscrew ........................................................................................................... 3
8 1528482 Capscrew ........................................................................................................... 1
8 1398062 Nut ...................................................................................................................... 1
9 1686719 Bracket ................................................................................................................ 1
10 1562088 Clip ..................................................................................................................... 2

FOOTNOTES:
a Without Electronic Hydraulics

©2011 HYSTER COMPANY See Service Manual 4-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM (FIGURE 4-7)

TRANSMISSION

4-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRICAL SYSTEM
TRANSMISSION
KEY:
A: Single Speed
B: Dual Speed
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 2085943 Wire Harness (Transmission) (Single Speed) (FFigure 4-53)................... 1 ..
1 2085942 Wire Harness (Transmission) (Dual Speed) (FFigure 4-54)................ .. 1
2 a 287851 Capscrew ................................................................................................... 2 2
3 a 292681 Lockwasher .............................................................................................. 2 2
4 a 1612223 Bracket ....................................................................................................... 1 1
5 a 1616222 Bracket ....................................................................................................... 1 ..
6 1612399 Bracket ....................................................................................................... .. 1

FOOTNOTES:
a → PENDING PER ECN 104796

©2011 HYSTER COMPANY See Service Manual 4-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM (FIGURE 4-8)

MAST

ITEM PART NO. DESCRIPTION QTY

1 1625255 Bracket ................................................................................................................ 1
2 1586430 Nut ...................................................................................................................... 1
3 1595731 Bracket ................................................................................................................ 1
4 1595234 Sensor (Mast Tilt Position) .................................................................................. 1
5 1562088 Clip ...................................................................................................................... 1
6 1597451 Capscrew ............................................................................................................ 1
7 302398 Locknut ............................................................................................................... 2
8 1553897 Capscrew ............................................................................................................ 2
9 1626478 Washer ............................................................................................................... 1
10 1658075 Capscrew ............................................................................................................ 1

4-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRICAL SYSTEM (FIGURE 4-9)

LOAD WEIGH

4-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRICAL SYSTEM
LOAD WEIGH

ITEM PART NO. DESCRIPTION QTY

1 2079326 Wire Harness (Load Weigh) ............................................................................... 1
2 1525565 Connector ....................................................................................................... 1
2 1500913 Connector ....................................................................................................... 1
2 1330438 Terminal (Socket) ........................................................................................... 3
2 1484377 Plug ................................................................................................................ 9
3 1603021 Connector ....................................................................................................... 1
3 1603236 Connector (Secondary Lock) .......................................................................... 1
3 1548517 Terminal (Socket) ........................................................................................... 3
3 1548519 Seal ................................................................................................................ 3
4 1606544 Clamp ................................................................................................................. 3
5 1573549 Clamp ................................................................................................................. 3
6 1606735 Sensor (Load Sensing) ....................................................................................... 1
7 1648259 Fitting .................................................................................................................. 1

©2011 HYSTER COMPANY See Service Manual 4-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

POWER DISTRIBUTION MODULE (FIGURE 4-10)

(→ S/N G004V01735D)

4-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ITEM PART NO. DESCRIPTION QTY

2063093 Module ................................................................................................................ 1
1 2044712 Relay (30 Amp) .............................................................................................. 2
2 1528315 Relay (20 Amp) .............................................................................................. 5
3 1528132 Fuse (20 Amp) ................................................................................................ 5
4 1528133 Fuse (30 Amp) ................................................................................................ 2
5 1528630 Semiconductor ............................................................................................... 1
6 1528631 Resistor (68 Ohm, 5 Watt) .............................................................................. 1
7 1544255 Fuse (25 Amp) ................................................................................................ 3

©2011 HYSTER COMPANY See Service Manual 4-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

POWER DISTRIBUTION MODULE (FIGURE 4-11)

(S/N G004V01736D →)

4-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

POWER DISTRIBUTION MODULE

(S/N G004V01736D →)

ITEM PART NO. DESCRIPTION QTY

2090613 Module ............................................................................................................... 1
1 2044712 Relay (30 Amp) ............................................................................................. 2
2 1528315 Relay (20 Amp) ............................................................................................. 5
3 1528132 Fuse (20 Amp) ............................................................................................... 6
4 1528133 Fuse (30 Amp) ............................................................................................... 2
5 1528630 Semiconductor ............................................................................................. 1
6 1528631 Resistor (68 Ohm, 5 Watt) ............................................................................ 1
7 1544255 Fuse (25 Amp) ............................................................................................... 2

©2011 HYSTER COMPANY See Service Manual 4-29

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL LEVERS (FIGURE 4-12)

MINI-LEVER MODULES — DATE CODE 0724

4-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL LEVERS

MINI-LEVER MODULES – DATE CODE 0724
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
1 2064790 Mini-Lever (Plain, 8522697) (Without Clamping) .............................. 1 .. ..
1 2075911 Mini-Lever (Clamping, 8528542) ....................................................... 1 .. ..
1 2075913 Mini-Lever (Return To Set Tilt, 8528544) .......................................... 1 .. ..
1 2075916 Mini-Lever (Clamping and Return To Set Tilt, 8528546) ................... 1 .. ..
1 1683379 Kit-Mini-Lever (Non-Clamping) ...................................................... AR .. ..
1 1683398 Kit-Mini-Lever (Clamping) ............................................................. AR .. ..
1 1658063 Handle (Mini-Lever) ....................................................................... 1 .. ..
2 1598222 Kit-Plug (Mini-Lever Plug) ............................................................. 1 .. ..
3 2064807 Mini-Lever (Plain, 8522700) (Without Clamping) .............................. .. 1 ..
3 2075912 Mini-Lever (Clamping, 8528543) ....................................................... .. 1 ..
3 2075914 Mini-Lever (Return To Set Tilt, 8528545) .......................................... .. 1 ..
3 2075917 Mini-Lever (Clamping And Return To Set Tilt, 8528547) .................. .. 1 ..
3 2085519 Mini-Lever (Plain, 8533576) .............................................................. .. .. 1
3 2085520 Mini-Lever (Clamping, 8533577) ....................................................... .. .. 1
3 2085521 Mini-Lever (Return To Set Tilt, 8533578) .......................................... .. .. 1
3 2085522 Mini-Lever (Clamping and Return To Set Tilt, 8533579) ................... .. .. 1
3 1658063 Handle (Mini-Lever) ....................................................................... .. 1 1
3 1683398 Kit-Mini-Lever (Clamping) ............................................................. .. AR AR
3 1683379 Kit-Mini-Lever (Non-Clamping) ...................................................... .. AR AR
4 ..... Label ............................................................................................. 1 1 1
5 1598221 Kit-Switch (Interlock Switch) .......................................................... AR AR AR
5 1591181 Switch-Momentary .................................................................... 1 1 1
5 1598223 Kit-Plug (Interlock Switch Plug) ..................................................... AR AR AR
6 1514429 Nut ................................................................................................. 4 4 ..

©2011 HYSTER COMPANY See Service Manual 4-31

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL LEVERS (FIGURE 4-13)

MINI-LEVER MODULES (THREE FUNCTION) — DATE CODE 0725 THROUGH 0743

4-32 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL LEVERS

MINI-LEVER MODULES (THREE FUNCTION) – DATE CODE 0725 THROUGH 0743

ITEM PART NO. DESCRIPTION QTY

1 2099224 Mini-Lever (Plain, 8542298) ................................................................................ 1
b 1598222 Kit-Plug (Mini-Lever Plug) .............................................................................. 1
c 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 3
1 2099228 Mini-Lever (Clamping, 8542302) ........................................................................ 1
a 1683398 Kit-Mini-Lever (Clamping) ............................................................................... 1
d 1598221 Kit-Switch (Interlock Switch) ........................................................................... 1
b 1598222 Kit-Plug (Mini-Lever Plug) .............................................................................. 1
c 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 2
1 2099230 Mini-Lever (Return To Set Tilt, 8542304) ........................................................... 1
a 1683398 Kit-Mini-Lever (Clamping) ............................................................................... 1
d 1598221 Kit-Switch (Interlock Switch) ........................................................................... 1
b 1598222 Kit-Plug (Mini-Lever Plug) .............................................................................. 1
c 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 2
1 2099233 Mini-Lever (Clamping and Return To Set Tilt, 8542307) .................................... 1
a 1591185 Kit-Lever (Interlock Mini-Lever) ...................................................................... 1
d 1598221 Kit-Switch (Interlock Switch) ........................................................................... 1
b 1598224 Plug ................................................................................................................ 1
c 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 2
2 ..... Plug (Momentary Switch) ............................................................................... AR
3 1591181 Switch-Momentary .......................................................................................... AR
4 ..... Mini-Lever ....................................................................................................... AR
4 1658063 Handle (Mini-Lever) .................................................................................... 1
5 ..... Label (Shows Production Part Number) ......................................................... 1
6 1598224 Plug (Mini-Lever) ............................................................................................ 1
7 ..... Control Labels ..................................................................................................... 1

FOOTNOTES:
a Kit Includes: 1 Interlock Rocker (must be used in c Kit Includes: 1 Momentary Interlock Switch Plug, 1
combination with a Momentary Interlock Switch), 1 Gasket (parts are NSS)
Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Momentary Switch, 1 Lockwasher,
b Kit Includes: 1 Mini-Lever Plug, 1 Gasket (parts are 1 Gasket, 1 Nut (parts are NSS)
NSS)

©2011 HYSTER COMPANY See Service Manual 4-33

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL LEVERS (FIGURE 4-14)

MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) — DATE CODE 0725 THROUGH 0743

4-34 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL LEVERS

MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) – DATE CODE 0725 THROUGH 0743
KEY:
A: Four Function
B: Five Function
QTY
ITEM PART NO. DESCRIPTION A B
1 2099225 Mini-Lever (Plain, 8542299) ....................................................................... 1 ..
b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 3 ..
d 1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. 3 ..
1 2099229 Mini-Lever (Clamping, 8542303) ................................................................ 1 ..
1 1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. 2 ..
c 1683398 Kit-Mini-Lever (Clamping) ...................................................................... 1 ..
b 1598221 Kit-Switch (Interlock Switch) .................................................................. 1 ..
1 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 2 ..
1 2099231 Mini-Lever (Return To Set Tilt, 8542305) ................................................... 1 ..
d 1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. 2 ..
1 1683398 Kit-Mini-Lever (Clamping) ...................................................................... 1 ..
c 1598221 Kit-Switch (Interlock Switch) .................................................................. 1 ..
b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 2 ..
1 2099234 Mini-Lever (Clamping And Return To Set Tilt, 8542308) ........................... 1 ..
a 1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. 2 ..
c 1598221 Kit-Switch (Interlock Switch) .................................................................. 1 ..
b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 2 ..
1 2099235 Mini-Lever (Plain, 8542309) ....................................................................... .. 1
1 d 1555731 Kit-Mini-Lever (Plain Mini-Lever) ........................................................... .. 3
1 a 1591185 Kit-Lever (Interlock Mini-Lever) .............................................................. .. 1
1 b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. .. 2
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
1 2099236 Mini-Lever (Clamping, 8542310) ................................................................ .. 1
1 b 1555731 Kit-Mini-Lever (Plain Mini-Lever) ........................................................... .. 2
1 a 1591185 Kit-Lever (Interlock Mini-Lever) .............................................................. .. 2
1 c 1598221 Kit-Switch (Interlock Switch) .................................................................. .. 1
1 b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. .. 1
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
1 2099237 Mini-Lever (Return To Set Tilt, 8542311) ................................................... .. 1
1 d 1555731 Kit-Mini-Lever (Plain Mini-Lever) ........................................................... .. 2
1 a 1591185 Kit-Lever (Interlock Mini-Lever) .............................................................. .. 1
1 c 1598221 Kit-Switch (Interlock Switch) .................................................................. .. 1
1 b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. .. 1
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
1 2099238 Mini-Lever (Clamping and Return To Set Tilt, 8542312) ........................... .. 1
1 d 1555731 Kit-Mini-Lever (Plain Mini-Lever) ........................................................... .. 1
1 a 1591185 Kit-Lever (Interlock Mini-Lever) .............................................................. .. 3
1 c 1598221 Kit-Switch (Interlock Switch) .................................................................. .. 2
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
2 1591181 Switch-Momentary ................................................................................. AR AR
3 ..... Plug (Momentary Switch) ....................................................................... AR AR
4 ..... Mini-Lever .............................................................................................. AR AR
4 1658063 Handle (Mini-Lever) ........................................................................... 1 1
5 ..... Label ...................................................................................................... 1 1
6 ..... Control Labels ............................................................................................ 1 1

©2011 HYSTER COMPANY See Service Manual 4-35

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a Kit Includes: 1 Interlock Mini-Lever (must be used c Kit Includes: 1 Momentary Switch, 1 Lockwasher,
in combination with a Momentary Interlock Switch), 1 Gasket, 1 Nut (parts are NSS)
1 Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Plain Mini-Lever, 1 Gasket, 4
b Kit Includes: 1 Momentary Switch Hole Plug, 1 Screws (parts are NSS)
Gasket (parts are NSS)

4-36 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-37

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL LEVERS (FIGURE 4-15)

MINI-LEVER MODULES (THREE FUNCTION) — DATE CODE 0744

4-38 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL LEVERS

MINI-LEVER MODULES (THREE FUNCTION) – DATE CODE 0744

ITEM PART NO. DESCRIPTION QTY

1 2105372 Mini-Lever (8544613) .......................................................................................... 1
1689455 Kit-Mini-Lever (Non-Clamping) ....................................................................... 3
b 1598224 Plug ................................................................................................................ 1
c 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 3
1 2105376 Mini-Lever (8544617) (With Clamping) ............................................................... 1
a 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 1
d 1598221 Kit-Switch (Interlock Switch) ........................................................................... 1
b 1598224 Plug ................................................................................................................ 1
c 1689455 Kit-Mini-Lever (Non-Clamping) ....................................................................... 2
1689460 Kit-Mini-Lever (Clamping) ............................................................................... 1
1 2105378 Mini-Lever (8544619) (With Return To Set Tilt) .................................................. 1
a 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 2
d 1598221 Kit-Switch (Interlock Switch) ........................................................................... 1
b 1598224 Plug ................................................................................................................ 1
c 1689455 Kit-Mini-Lever (Non-Clamping) ....................................................................... 2
1689460 Kit-Mini-Lever (Clamping) ............................................................................... 1
1 2105380 Mini-Lever (8544621) (With Clamping and Return to set Tilt) ............................ 1
d 1598221 Kit-Switch (Interlock Switch) ........................................................................... 2
b 1598224 Plug ................................................................................................................ 2
c 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 1
1689455 Kit-Mini-Lever (Non-Clamping) ....................................................................... 1
1689460 Kit-Mini-Lever (Clamping) ............................................................................... 2
1 2103849 Mini-Lever (8543799) .......................................................................................... 1
1683379 Kit-Mini-Lever (Non-Clamping) ....................................................................... 3
c 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 3
1 1598224 Plug ................................................................................................................ 1
1 2103853 Mini Lever (8543802) (With Clamping) ............................................................... 1
1683379 Kit-Mini-Lever (Non-Clamping) ....................................................................... 2
1683398 Kit-Mini-Lever (Clamping) ............................................................................... 1
1 d 1598221 Kit-Switch (Interlock Switch) ........................................................................... 1
1 c 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 2
1598224 Plug ................................................................................................................ 1
1 2103857 Mini Lever (8543807) (Clamping With Return To Set Tilt) .................................. 1
1683379 Kit-Mini-Lever (Non-Clamping) ....................................................................... 1
1683398 Kit-Mini-Lever (Clamping) ............................................................................... 2
1 d 1598221 Kit-Switch (Interlock Switch) ........................................................................... 2
1 c 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 1
1 1598224 Plug ................................................................................................................ 2
1 2103855 Mini Lever (8543805) (With Return to Set Tilt) ................................................... 1
1683379 Kit-Mini-Lever (Non-Clamping) ....................................................................... 2
1683398 Kit-Mini-Lever (Clamping) ............................................................................... 1
1 d 1598221 Kit-Switch (Interlock Switch) ........................................................................... 1
1 c 1598223 Kit-Plug (Interlock Switch Plug) ...................................................................... 2
1 1598224 Plug ................................................................................................................ 1
2 ..... Plug (Momentary Switch) ............................................................................... AR
3 1591181 Switch-Momentary .......................................................................................... AR
4 ..... Mini-Lever ....................................................................................................... AR
4 1658063 Handle (Mini-Lever) .................................................................................... 1
5 ..... Label (Shows Production Part Number) ......................................................... 1
6 1598224 Plug (Mini-Lever) ............................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 4-39

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL LEVERS

MINI-LEVER MODULES (THREE FUNCTION) – DATE CODE 0744

ITEM PART NO. DESCRIPTION QTY

7 ..... Control Labels ..................................................................................................... 1

FOOTNOTES:
a Kit Includes: 1 Interlock Rocker (must be used in c Kit Includes: 1 Momentary Interlock Switch Plug, 1
combination with a Momentary Interlock Switch), 1 Gasket (parts are NSS)
Gasket, 4 Screws (parts are NSS) d Kit Includes: 1 Momentary Switch, 1 Lockwasher,
b Kit Includes: 1 Mini-Lever Plug, 1 Gasket (parts are 1 Gasket, 1 Nut (parts are NSS)
NSS)

4-40 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-41

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL LEVERS (FIGURE 4-16)

MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) — DATE CODE 0744

4-42 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL LEVERS

MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) – DATE CODE 0744
KEY:
A: Four Function
B: Five Function
QTY
ITEM PART NO. DESCRIPTION A B
1 2105373 Mini-Lever (8544614) ................................................................................. 1 ..
1689455 Kit-Mini-Lever (Non-Clamping) .............................................................. 4 ..
b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 3 ..
1 2105377 Mini-Lever (8544618) (With Clamping) ...................................................... 1 ..
1689455 Kit-Mini-Lever (Non-Clamping) .............................................................. 3 ..
1689460 Kit-Mini-Lever (Clamping) ...................................................................... 1 ..
c 1598221 Kit-Switch (Interlock Switch) .................................................................. 1 ..
b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 1 ..
1 2105379 Mini-Lever (8544620) (With Return to Set Tilt) .......................................... 1 ..
1689455 Kit-Mini-Lever (Non-Clamping) .............................................................. 3 ..
a 1689460 Kit-Mini-Lever (Clamping) ...................................................................... 1 ..
c 1598221 Kit-Switch (Interlock Switch) .................................................................. 1 ..
b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 2 ..
1 2105381 Mini-Lever (8544622) (Clamping and Return to Set Tilt) ........................... 1 ..
1689455 Kit-Mini-Lever (Non-Clamping) .............................................................. 2 ..
c 1598221 Kit-Switch (Interlock Switch) .................................................................. 2 ..
b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 1 ..
1 1689460 Kit-Mini-Lever (Clamping) ...................................................................... 2 ..
1 2103850 Mini Lever (8543800) ................................................................................. 1 ..
1 1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. 4 ..
1 b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 3 ..
1 2103854 Mini Lever (8543804) (With Clamping) ...................................................... 1 ..
1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. 3 ..
1683398 Kit-Mini-Lever (Clamping) ...................................................................... 1 ..
c 1598221 Kit-Switch (Interlock Switch) .................................................................. 1 ..
b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 2 ..
1 2103856 Mini Lever (8543806) (With Return to Set Tilt) ........................................... 1 ..
1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. 3 ..
1683398 Kit-Mini-Lever (Clamping) ...................................................................... 1 ..
c 1598221 Kit-Switch (Interlock Switch) .................................................................. 1 ..
b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 2 ..
1 2103858 Mini Lever (8543808) (Clamping with Return to Set Tilt) ........................... 1 ..
1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. 2 ..
1683398 Kit-Mini-Lever (Clamping) ...................................................................... 2 ..
c 1598221 Kit-Switch (Interlock Switch) .................................................................. 2 ..
b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. 1 ..
1 2105382 Mini-Lever (8544623) ................................................................................. .. 1
1 1689455 Kit-Mini-Lever (Non-Clamping) .............................................................. .. 3
1 1689460 Kit-Mini-Lever (Clamping) ...................................................................... .. 1
1 b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. .. 2
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
1 2105383 Mini-Lever (8544624) (With Clamping) ...................................................... .. 1
1 1689455 Kit-Mini-Lever (Non-Clamping) .............................................................. .. 2
1 1689460 Kit-Mini-Lever (Clamping) ...................................................................... .. 2
1 c 1598221 Kit-Switch (Interlock Switch) .................................................................. .. 1

©2011 HYSTER COMPANY See Service Manual 4-43

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL LEVERS

MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) – DATE CODE 0744
KEY:
A: Four Function
B: Five Function
QTY
ITEM PART NO. DESCRIPTION A B
1 b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. .. 1
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
1 2105384 Mini-Lever (8544625) (Return to Set Tilt) ................................................... .. 1
1 1689455 Kit-Mini-Lever (Non-Clamping) .............................................................. .. 2
1 1689460 Kit-Mini-Lever (Clamping) ...................................................................... .. 2
1 c 1598221 Kit-Switch (Interlock Switch) .................................................................. .. 1
1 b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. .. 1
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
1 2105385 Mini-Lever (8544626) (Clamping with Return to Set Tilt) ........................... .. 1
1 1689455 Kit-Mini-Lever (Non-Clamping) .............................................................. .. 1
1 1689460 Kit-Mini-Lever (Clamping) ...................................................................... .. 3
1 c 1598221 Kit-Switch (Interlock Switch) .................................................................. .. 2
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
1 2103859 Mini Lever (8543809) ................................................................................. .. 1
1 1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. .. 3
1 1683398 Kit-Mini-Lever (Clamping) ...................................................................... .. 1
1 b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. .. 2
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
1 2103860 Mini Lever (8543810) (With Clamping) ...................................................... .. 1
1 1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. .. 2
1 1683398 Kit-Mini-Lever (Clamping) ...................................................................... .. 2
1 c 1598221 Kit-Switch (Interlock Switch) .................................................................. .. 1
1 b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. .. 1
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
1 2103861 Mini Lever (8543811) (Return to Set Tilt) ................................................... .. 1
1 1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. .. 2
1 1683398 Kit-Mini-Lever (Clamping) ...................................................................... .. 2
1 c 1598221 Kit-Switch (Interlock Switch) .................................................................. .. 1
1 b 1598223 Kit-Plug (Interlock Switch Plug) ............................................................. .. 1
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
1 2103862 Mini Lever (8543812) (Clamping with Return to Set Tilt) ........................... .. 1
1 1683379 Kit-Mini-Lever (Non-Clamping) .............................................................. .. 1
1 1683398 Kit-Mini-Lever (Clamping) ...................................................................... .. 3
1 c 1598221 Kit-Switch (Interlock Switch) .................................................................. .. 2
1 1619962 Kit-Switch (Mini-Lever Interlock Switch) ................................................ .. 1
2 1591181 Switch-Momentary ................................................................................. AR AR
3 ..... Plug (Momentary Switch) ....................................................................... AR AR
4 ..... Mini-Lever .............................................................................................. AR AR
4 1658063 Handle (Mini-Lever) ........................................................................... 1 1
5 ..... Label ...................................................................................................... 1 1
6 ..... Control Labels ............................................................................................ 1 1

4-44 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FOOTNOTES:
a Kit Includes: 1 Interlock Mini-Lever (must be used c Kit Includes: 1 Momentary Switch, 1 Lockwasher,
in combination with a Momentary Interlock Switch), 1 Gasket, 1 Nut (parts are NSS)
1 Gasket, 4 Screws (parts are NSS)
b Kit Includes: 1 Momentary Switch Hole Plug, 1
Gasket (parts are NSS)

©2011 HYSTER COMPANY See Service Manual 4-45

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MINI-LEVER CONTROLS (FIGURE 4-17)

WITH ARMREST — THREE FUNCTION (S/N G004V04680H → EXC. 04683)

4-46 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MINI-LEVER CONTROLS
WITH ARMREST – THREE FUNCTION (S/N G004V04680H → EXC. 04683)
KEY:
A: Without Directional Control Switch
B: With Directional Control Switch
QTY
ITEM PART NO. DESCRIPTION A B
1 4601093 Mini-Lever Assembly .................................................................................. 1 ..
1 c 4601265 Mini-Lever Assembly .................................................................................. 1 ..
1 a 4601097 Mini-Lever Assembly .................................................................................. 1 ..
1 b 4601099 Mini-Lever Assembly .................................................................................. 1 ..
1 4601101 Mini-Lever Assembly .................................................................................. .. 1
1 c 4601103 Mini-Lever Assembly .................................................................................. .. 1
1 a 4601105 Mini-Lever Assembly .................................................................................. .. 1
1 b 4601107 Mini-Lever Assembly .................................................................................. .. 1
2 ..... Lever Position 1 ..................................................................................... 1 1
2 2110791 Lever (Single Function) ..................................................................... 1 1
3 ..... Lever Position 2 ..................................................................................... 1 1
3 2110791 Lever (Single Function) ..................................................................... 1 1
3 a 2110793 Lever (With Override) ........................................................................ 1 1
4 ..... Lever Position 3 ..................................................................................... 1 1
4 2110791 Lever (Single Function) ..................................................................... 1 1
4 c 2110792 Lever (Clamping) ............................................................................... 1 1
5 2108249 Plug ........................................................................................................ 1 1
6 2111799 Armrest (Without Holes) ........................................................................ 1 1
6 ac 4603439 Armrest (With Holes) ............................................................................. 1 1
7 2111769 Cushion (Armrest) .................................................................................. 1 1
8 1709587 Nut ......................................................................................................... 5 5
9 1698449 Capscrew ............................................................................................... 6 6
10 4605336 Wire Harness ......................................................................................... 1 1
11 c 1591181 Switch-Momentary ................................................................................. 1 1
11 b 1591181 Switch-Momentary ................................................................................. 2 2
12 c 1598225 Hole Plug ............................................................................................... 2 2
12 b 1598225 Hole Plug ............................................................................................... 1 1
13 1704529 Wire Harness (Push Buttons) ................................................................ 1 1
14 2111802
4605337 Printed Circuit Board .............................................................................. 1 1
15 2111800 Cover (Bottom Armrest) ......................................................................... 1 1
16 4601120 Plug ........................................................................................................ 1 1
17 2111770 Horn Button ............................................................................................ 1 1
18 2110943 Switch (Directional Control) ................................................................... .. 1
19 2110942 Plug (Directional Control Switch) ........................................................... 1 ..
20 1698449 Capscrew ................................................................................................... 8 8

FOOTNOTES:
a Return to Set Tilt c With Clamping
b Three Function Clamp with Return to Set Tilt

©2011 HYSTER COMPANY See Service Manual 4-47

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MINI-LEVER CONTROLS (FIGURE 4-18)

WITH ARMREST — FOUR FUNCTION (S/N G004V04680H → EXC. 04683)

4-48 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MINI-LEVER CONTROLS
WITH ARMREST – FOUR FUNCTION (S/N G004V04680H → EXC. 04683)
KEY:
A: Without Directional Control Switch
B: With Directional Control Switch
QTY
ITEM PART NO. DESCRIPTION A B
1 4601094 Mini-Lever Assembly .................................................................................. 1 ..
1 a 4601096 Mini-Lever Assembly .................................................................................. 1 ..
1 c 4601098 Mini-Lever Assembly .................................................................................. 1 ..
1 b 4601100 Mini-Lever Assembly .................................................................................. 1 ..
1 4601102 Mini-Lever Assembly .................................................................................. .. 1
1 a 4601104 Mini-Lever Assembly .................................................................................. .. 1
1 c 4601106 Mini-Lever Assembly .................................................................................. .. 1
1 b 4601108 Mini-Lever Assembly .................................................................................. .. 1
2 ..... Lever Position 1 ..................................................................................... 1 1
2 2110791 Lever (Single Function) ..................................................................... 1 1
3 ..... Lever Position 2 ..................................................................................... 1 1
3 2110791 Lever (Single Function) ..................................................................... 1 1
3 b 2110793 Lever (With Override) ........................................................................ 1 1
4 ..... Lever Position 3 ..................................................................................... 1 1
4 2110791 Lever (Single Function) ..................................................................... 1 1
5 ..... Lever Position 4 ..................................................................................... 1 1
5 2110791 Lever (Single Function) ..................................................................... 1 1
5 ab 2110792 Lever (Clamping) ............................................................................... 1 1
6 2111799 Armrest (Without Holes) ........................................................................ 1 1
6 abc 4603439 Armrest (With Holes) ............................................................................. 1 1
7 2111769 Cushion (Armrest) .................................................................................. 1 1
8 1709587 Nut ......................................................................................................... 5 5
9 1698449 Capscrew ............................................................................................... 6 6
10 4605336 Wire Harness ......................................................................................... 1 1
11 a 1591181 Switch-Momentary ................................................................................. 1 1
11 b 1591181 Switch-Momentary ................................................................................. 2 2
12 a 1598225 Hole Plug ............................................................................................... 2 2
12 b 1598225 Hole Plug ............................................................................................... 1 1
13 1704529 Wire Harness (Push Buttons) ................................................................ 1 1
14 2111802
4605337 Printed Circuit Board .............................................................................. 1 1
15 2111800 Cover (Bottom Armrest) ......................................................................... 1 1
16 4601120 Plug ........................................................................................................ 1 1
17 2111770 Horn Button ............................................................................................ 1 1
18 2110943 Switch (Directional Control) ................................................................... .. 1
19 2110942 Plug (Directional Control Switch) ........................................................... 1 ..
20 1698449 Capscrew ................................................................................................... 8 8

FOOTNOTES:
a With Clamping c With Return to Set Tilt
b With Clamping and Return to Set Tilt

©2011 HYSTER COMPANY See Service Manual 4-49

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MINI-LEVER CONTROLS (FIGURE 4-19)

WITH ARMREST — FIVE FUNCTION (S/N G004V04680H → EXC. 04683)

4-50 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MINI-LEVER CONTROLS
WITH ARMREST – FIVE FUNCTION (S/N G004V04680H → EXC. 04683)
KEY:
A: Without Directional Control Switch
B: With Directional Control Switch
QTY
ITEM PART NO. DESCRIPTION A B
1 4601110 Mini-Lever .................................................................................................. 1 ..
1 b 4601112 Mini-Lever .................................................................................................. 1 ..
1 a 4601114 Mini-Lever .................................................................................................. .. 1
1 b 4601116 Mini-Lever .................................................................................................. .. 1
2 ..... Lever Position 1 ..................................................................................... 1 1
2 2110791 Lever (Single Function) ..................................................................... 1 1
3 ..... Lever Position 2 ..................................................................................... 1 1
3 2110791 Lever (Single Function) ..................................................................... 1 1
3 b 2110793 Lever (With Override) ........................................................................ 1 1
4 ..... Lever Position 3 ..................................................................................... 1 1
4 2111796 Mini-Lever (Dual Function) ................................................................ 1 1
5 ..... Lever Position 4 ..................................................................................... 1 1
5 2110792 Lever (Clamping) ............................................................................... 1 1
6 4603440 Armrest (with Buttons) ........................................................................... 1 1
7 2111769 Cushion (Armrest) .................................................................................. 1 1
8 1709587 Nut ......................................................................................................... 5 5
9 1698449 Capscrew ............................................................................................... 6 6
10 4605336 Wire Harness ......................................................................................... 1 1
11 ..... Push Button Position 2 .......................................................................... 1 1
11 1598225 Hole Plug ........................................................................................... 1 1
11 ..... Push Button Position 3 .......................................................................... 1 1
11 1703775 Switch (Dual Function) ...................................................................... 1 1
11 ..... Push Button Position 4 .......................................................................... 1 1
11 1591181 Switch-Momentary ............................................................................. 1 1
12 1704529 Wire Harness (Push Buttons) ................................................................ 1 1
13 2111802
4605337 Printed Circuit Board .............................................................................. 1 1
14 2111800 Cover (Bottom Armrest) ......................................................................... 1 1
15 4601120 Plug ........................................................................................................ 1 1
16 2111770 Horn Button ............................................................................................ 1 1
17 2110943 Switch (Directional Control) ................................................................... .. 1
18 2110942 Plug (Directional Control Switch) ........................................................... 1 ..
19 1698449 Capscrew ................................................................................................... 8 8

FOOTNOTES:
a With Clamping b With Clamping and Return to Set Tilt

©2011 HYSTER COMPANY See Service Manual 4-51

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

REMOTE KEY SWITCH (FIGURE 4-20)

ITEM PART NO. DESCRIPTION QTY

1 1582337 Bracket ................................................................................................................ 1
2 1500912 Clip ...................................................................................................................... 1
3 1582464 Fastener .............................................................................................................. 1
4 a 2074320 Wire Harness (Remote Keyswitch) ..................................................................... 1
4 b 2058110 Wire Harness (Remote Keyswitch) ..................................................................... 1
4 1493465 Connector ....................................................................................................... 1
4 1330414 Connector (Secondary Lock) .......................................................................... 1
4 1330437 Terminal (Pin) ................................................................................................. 2
4 1521309 Connector Body .............................................................................................. 2
5 190380 Boot .................................................................................................................... 1
6 a 254007 Ignition Switch (Key) ........................................................................................... 1
6 b 2058111 Ignition Switch ..................................................................................................... 1
6 262798 Key Set ........................................................................................................... 1

FOOTNOTES:
a → S/N G004V02503E b S/N G004V02504E →

4-52 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

SEALED ALTERNATOR AND MOUNTING (FIGURE 4-21)

GM 4.3L

ITEM PART NO. DESCRIPTION QTY

1 1590098 Bracket ................................................................................................................ 1
2 1554815 Spacer ................................................................................................................ 1
3 1394001 Alternator (Sealed) .............................................................................................. 1
4 1307994 Capscrew ............................................................................................................ 1
5 1532255 Pulley .................................................................................................................. 1
6 18508 Capscrew ............................................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 4-53

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STARTER (FIGURE 4-22)

GM 4.3L, GS AND LPS

4-54 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

STARTER
GM 4.3L, GS AND LPS

ITEM PART NO. DESCRIPTION QTY

1 2109666 Dust Shield ........................................................................................................ 1
2 1534417 Capscrew ........................................................................................................... 2
2 148962 Capscrew (Alternate Part) ................................................................................ 1
3 1640531 Starter ................................................................................................................ 1
4 1640818 Bracket (Heat Shield) ........................................................................................ 1
5 264148 Nut ...................................................................................................................... 2
6 1677876 Bolt ..................................................................................................................... 2

©2011 HYSTER COMPANY See Service Manual 4-55

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DISTRIBUTOR ASSEMBLY (FIGURE 4-23)

ITEM PART NO. DESCRIPTION QTY

1559695 Distributor Assembly ....................................................................................... 1
1 1566458 Distributor Cap ............................................................................................. 1
2 1566459 Rotor .............................................................................................................. 1
3 1559922 Kit-Gear ......................................................................................................... 1
4 1334423 Gasket ........................................................................................................... 1
5 1559923 Sensor (Cam) ................................................................................................ 1
6 1559924 Screw ............................................................................................................. 4
7 1559925 Screw ............................................................................................................. 2
8 1335497 Clamp ............................................................................................................ 1

4-56 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INSTRUMENT CLUSTER (FIGURE 4-24)

ITEM PART NO. DESCRIPTION QTY

1 b 2060837 Lever (Detent Forward and Reverse) ................................................................. 1
1 d 2090110 Lever (Detent Forward and Reverse) ................................................................. 1
1 ce 2102904 Lever (Detent Forward and Reverse) ................................................................. 1
1 f 4604594 Lever ................................................................................................................... 1
2 2076695 Display ............................................................................................................... 1
3 2066485 Bezel (Display Cluster) ................................................................................ 2
4 2069431 Label (Blank) (LH Display) ........................................................................... 1
5 2066484 Label (RH Display, All Options) ....................................................................... 1
6 2060032 Cover (Display Lever) ....................................................................................... 1
7 1337197 Key Set ............................................................................................................... 1
8 2057948 Ignition Switch (Without Keys) ........................................................................ 1
9 1527879 Capscrew ........................................................................................................... 4
10 1554902 Screw ................................................................................................................. 5
11 2060033 Cover (Keyswitch) ............................................................................................... 1
12 a 2066482 Label (RH Display) ............................................................................................ 1

FOOTNOTES:
a Remove Panels From Overlay as Required For d S/N G004V01607D ↔ S/N G004V03492F
Truck Configuration. e S/N G004V03493F →
b → S/N G004V01606D f S/N G004V04627H →
c → S/N G004V04626H

©2011 HYSTER COMPANY See Service Manual 4-57

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WORK, REAR DRIVE, AND BRAKE/TAIL LIGHTS (FIGURE 4-25)

4-58 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WORK, REAR DRIVE, AND BRAKE/TAIL LIGHTS

ITEM PART NO. DESCRIPTION QTY
1 2056824 Brake/Backup Light (Stop,Turn,Tail, And Back-Up) ........................................... 2
1 b 2056826 Reflector (Tail) ................................................................................................... 2
1 ..... Bracket ............................................................................................................... 2
2 1560448 Grommet ............................................................................................................ 1
3 1302024 Guard ................................................................................................................. 1
4 c 2064836 Work Light (Rear) ............................................................................................... 1
4 i 2098083 Work Light (Rear) .............................................................................................. 1
4 2107382 Head/Work Light (Rear) ...................................................................................... 1
4 c 2064837 Work Light (RH Front) ......................................................................................... 1
4 2098082 Bulb (Halogen) .............................................................................................. 1
4 i 2098084 Work Light (RH Front) ...................................................................................... 1
4 2107383 Head/Work Light (RH Front) (LED) ..................................................................... 1
4 c 2064838 Work Light (LH Front) ......................................................................................... 1
4 2098082 Bulb (Halogen) .............................................................................................. 1
4 i 2098085 Work Light (LH Front) ....................................................................................... 1
a 2098082 Bulb (Halogen) (Work Light) ........................................................................ 1
4 2107384 Head/Work Light (LH Front) (LED) ..................................................................... 1
5 1539584 Grommet ............................................................................................................ 1
6 d 2073760 Wire Harness (Lights) (FFigure 4-55)................................................................ 1
6 g 2090084 Wire Harness (Lights) (FFigure 4-56)................................................................ 1
6 j 2098385 Wire Harness (Lights) (FFigure 4-57)............................................................. 1
7 1537551 Nut ...................................................................................................................... 4
8 1560447 Grommet ............................................................................................................ 1
9 1565125 Screw ................................................................................................................. 4
10 1531001 Insert .................................................................................................................. 2
11 1586759 Capscrew ........................................................................................................... 2
12 1565076 Bracket Wldmt ................................................................................................... 1
13 1586495 Capscrew ........................................................................................................... 2
14 1586428 Nut ...................................................................................................................... 2
15 e 1581670 Strobe Light (FFigure 13-2)............................................................................... 1
15 h 1654013 Strobe Light Assembly (FFigure 13-3)........................................................... 1
16 f 2095895 Wire Harness ...................................................................................................... 1
16 1514597 Connector ..................................................................................................... 1
16 1514598 Connector ..................................................................................................... 1
16 1484709 Terminal (Pin) ............................................................................................... 4
16 1634047 Resistor .......................................................................................................... 3
17 g 1644398 Clamp ................................................................................................................. 1
18 g 1606544 Clamp ................................................................................................................. 1

FOOTNOTES:
a Not Illustrated f S/N G004V01640D ↔ 6/2007
b Optional g S/N G004V01640D →
c → 4/2007 h S/N G004V02784E → INC. 02746, 02754-02758
d → S/N G004V01639D i 4/2007 →
e → S/N G004V02783E EXC. 02746, 02754-02758 j 6/2007 →

©2011 HYSTER COMPANY See Service Manual 4-59

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

IMPACT SENSOR (FIGURE 4-26)

4-60 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

IMPACT SENSOR
ITEM PART NO. DESCRIPTION QTY
1 1535166 Bracket ................................................................................................................ 1
2 1500912 Clip ...................................................................................................................... 2
3 1582464 Fastener .............................................................................................................. 2
3 2100710 Fastener (Alternate Part) .................................................................................... 1
4 2079281 Wire Harness (Impact Sensor) ........................................................................... 1
5 1489655 Connector (4 Way) ......................................................................................... 1
6 1330416 Connector ....................................................................................................... 1
7 1330437 Terminal (Pin) ................................................................................................. 4
8 1489656 Connector (4-Way) ......................................................................................... 2
9 1489657 Connector ....................................................................................................... 2
10 1330438 Terminal (Socket) ........................................................................................... 8
11 1561759 Clamp (Swivel) .................................................................................................... 2
12 1542439 Clamp (Swivel) .................................................................................................... 2
13 1502055 Clamp (Swivel) .................................................................................................... 1
14 1527879 Capscrew ............................................................................................................ 2
14 287851 Capscrew (Alternate Part) .................................................................................. 2
14 320157 Washer (Alternate Part) ...................................................................................... 2
15 2079843 Sensor (Impact) .................................................................................................. 1
16 1489655 Connector (4 Way) ......................................................................................... 1
17 1330416 Connector ....................................................................................................... 1
18 1330433 Terminal ......................................................................................................... 4
19 1502053 Clamp (Swivel) .................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-61

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-27)

RIGHT HAND CHASSIS — GM 4.3L (→ 8/2006)

4-62 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (→ 8/2006)

ITEM PART NO. DESCRIPTION QTY

2085952 Wire Harness ...................................................................................................... 1
1 1608857 Clip ................................................................................................................. 1
2 1509890 Clip ................................................................................................................. 3
3 ..... Connector Assembly (Oxygen Sensor) .......................................................... 1
3 1482667 Connector Body ......................................................................................... 1
3 1482663 Connector ................................................................................................... 1
3 1330356 Seal ............................................................................................................ 2
3 1476108 Wire Seal .................................................................................................... 2
3 1330355 Terminal ..................................................................................................... 4
4 ..... Connector Assembly (To Backup Alarm Harness) ......................................... 1
4 1490242 Connector ................................................................................................... 1
4 1490243 Connector ................................................................................................... 1
4 1330438 Terminal (Socket) ....................................................................................... 2
5 1626727 Connector (End Cap) ..................................................................................... 1
6 ..... Connector Assembly (Coolant Level) ............................................................. 1
6 1329152 Plug ............................................................................................................ 1
6 1329151 Terminal ..................................................................................................... 1
6 1330281 Terminal ..................................................................................................... 2
6 1402888 Seal ............................................................................................................ 2
7 ..... Connector Assembly (End Cap) ..................................................................... 1
7 1329150 Connector ................................................................................................... 1
7 1329151 Terminal ..................................................................................................... 1
7 1327164 Seal ............................................................................................................ 2
8 1509888 Clip ................................................................................................................. 2
9 ..... Connector Assembly (To Seat Harness) ........................................................ 1
9 1541991 Connector ................................................................................................... 1
9 1541992 Connector ................................................................................................... 1
9 1463139 Terminal ..................................................................................................... 8
10 1402815 Clip ................................................................................................................. 2
11 1525577 Connector (With Resistor) (End Cap) ............................................................. 1
12 ..... Connector Assembly (Power Distribution Module) ......................................... 1
12 1521186 Connector ................................................................................................... 1
12 1521188 Lock ............................................................................................................ 1
12 1323579 Seal ............................................................................................................ 7
12 1327164 Seal ............................................................................................................ 1
12 1521989 Terminal ..................................................................................................... 7
13 ..... Connector Assembly (Power Distribution Module) ......................................... 1
13 1521183 Connector ................................................................................................... 1
13 1521188 Lock ............................................................................................................ 1
13 1323579 Seal ............................................................................................................ 7
13 1327164 Seal ............................................................................................................ 1
13 1330281 Terminal ..................................................................................................... 4
13 1521989 Terminal ..................................................................................................... 3
14 ..... Connector Assembly (Power Distribution Module) ......................................... 1
14 1521184 Connector ................................................................................................... 1
14 1521188 Lock ............................................................................................................ 1
14 1323579 Seal ............................................................................................................ 5
14 1327164 Seal ............................................................................................................ 1
14 1330281 Terminal ..................................................................................................... 6
14 1521989 Terminal ..................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-63

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (→ 8/2006)

ITEM PART NO. DESCRIPTION QTY

14 1402888 Seal ............................................................................................................ 2
15 ..... Connector Assembly ...................................................................................... 1
15 1521185 Connector ................................................................................................... 1
15 1521188 Lock ............................................................................................................ 1
15 1323579 Seal ............................................................................................................ 8
15 1330281 Terminal ..................................................................................................... 5
15 1521989 Terminal ..................................................................................................... 3
16 1500899 Clip ................................................................................................................. 1
17 ..... Connector Assembly (To Transmission Harness) .......................................... 1
17 1525567 Connector ................................................................................................... 1
17 1529046 Connector ................................................................................................... 1
17 1463139 Terminal ..................................................................................................... 11
17 1484377 Plug ............................................................................................................ 1
18 ..... Connector Assembly (To Transmission Harness) .......................................... 1
18 1531973 Connector ................................................................................................... 1
18 1531974 Connector ................................................................................................... 1
18 1463139 Terminal ..................................................................................................... 6
19 ..... Connector Assembly ...................................................................................... 1
19 1531501 Connector (To Engine Harness) ................................................................ 1
19 1330438 Terminal (Socket) ....................................................................................... 15
19 1463139 Terminal ..................................................................................................... 6
19 1484377 Plug ............................................................................................................ 4
19 1554359 Terminal ..................................................................................................... 4
20 ..... Connector Assembly (To Lights and Cab Harness) ....................................... 1
20 1514597 Connector ................................................................................................... 1
20 1514602 Connector ................................................................................................... 1
20 1330439 Plug ............................................................................................................ 4
20 1514603 Connector ................................................................................................... 1
20 1554359 Terminal ..................................................................................................... 4
21 ..... Connector Assembly (End Cap) ..................................................................... 1
21 1514597 Connector ................................................................................................... 1
21 1330439 Plug ............................................................................................................ 4
22 ..... Connector Assembly (Accessory 1) ............................................................... 1
22 1545202 Connector ................................................................................................... 1
22 1546697 Connector ................................................................................................... 1
22 1554359 Terminal ..................................................................................................... 2
23 ..... Connector Assembly (End Cap) ..................................................................... 1
23 1480187 Connector ................................................................................................... 1
23 1330439 Plug ............................................................................................................ 2
24 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
24 1525570 Connector ................................................................................................... 1
24 1530037 Connector ................................................................................................... 1
24 1463139 Terminal ..................................................................................................... 8
24 1484377 Plug ............................................................................................................ 4
25 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
25 1525568 Connector ................................................................................................... 1
25 1530037 Connector ................................................................................................... 1
25 1463139 Terminal ..................................................................................................... 7
25 1484377 Plug ............................................................................................................ 5
26 ..... Connector Assembly (Vehicle System Manager) ........................................... 1

4-64 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (→ 8/2006)

ITEM PART NO. DESCRIPTION QTY

26 1525567 Connector ................................................................................................... 1
26 1530037 Connector ................................................................................................... 1
26 1463139 Terminal ..................................................................................................... 9
26 1484377 Plug ............................................................................................................ 3
27 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
27 1525563 Connector ................................................................................................... 1
27 1500913 Connector ................................................................................................... 1
27 1330438 Terminal (Socket) ....................................................................................... 8
27 1363886 Terminal (Socket) ....................................................................................... 4
28 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
28 1489655 Connector (4 Way) ..................................................................................... 1
28 1330416 Connector ................................................................................................... 1
28 1330437 Terminal (Pin) ............................................................................................. 4
29 ..... Connector Assembly (To Cowl Harness) ....................................................... 1
29 1493428 Connector (12-Way) ................................................................................... 1
29 1500913 Connector ................................................................................................... 1
29 1330438 Terminal (Socket) ....................................................................................... 9
29 1484377 Plug ............................................................................................................ 3
30 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
30 1525567 Connector ................................................................................................... 1
30 1529046 Connector ................................................................................................... 1
30 1463139 Terminal ..................................................................................................... 3
30 1484377 Plug ............................................................................................................ 9
31 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
31 1525569 Connector ................................................................................................... 1
31 1529046 Connector ................................................................................................... 1
31 1463139 Terminal ..................................................................................................... 3
31 1484377 Plug ............................................................................................................ 9
32 ..... Connector Assembly (To Horn) ...................................................................... 1
32 1476064 Connector ................................................................................................... 1
32 1476109 Connector Lock .......................................................................................... 1
32 1330356 Seal ............................................................................................................ 2
32 1330355 Terminal ..................................................................................................... 3
32 1476108 Wire Seal .................................................................................................... 1
33 1534282 Clip ................................................................................................................. 1
34 ..... Connector Assembly (To Hydraulic Filter) ...................................................... 1
34 1329152 Plug ............................................................................................................ 1
34 1329151 Terminal ..................................................................................................... 1
34 1330281 Terminal ..................................................................................................... 2
34 1402888 Seal ............................................................................................................ 2
35 ..... Connector Assembly (End Cap) ..................................................................... 1
35 1329150 Connector ................................................................................................... 1
35 1329151 Terminal ..................................................................................................... 1
35 1327164 Seal ............................................................................................................ 2
36 ..... Connector Assembly (Accessory 2) ............................................................... 1
36 1514602 Connector ................................................................................................... 1
36 1514603 Connector ................................................................................................... 1
36 1330439 Plug ............................................................................................................ 1
36 1554359 Terminal ..................................................................................................... 3
37 ..... Connector Assembly (End Cap) ..................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-65

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (→ 8/2006)

ITEM PART NO. DESCRIPTION QTY

37 1514597 Connector ................................................................................................... 1
37 1330439 Plug ............................................................................................................ 4
38 1626727 Connector (End Cap) ..................................................................................... 2
39 ..... Connector Assembly (Key Switch and Alternate Horn Button) ...................... 2
39 1490242 Connector ................................................................................................... 1
39 1490243 Connector ................................................................................................... 1
39 1330438 Terminal (Socket) ....................................................................................... 2
40 ..... Connector Assembly (Bus Terminal 2) ........................................................... 1
40 1489656 Connector (4-Way) ..................................................................................... 1
40 1489657 Connector ................................................................................................... 1
40 1330438 Terminal (Socket) ....................................................................................... 4

4-66 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-67

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-28)

RIGHT HAND CHASSIS — GM 4.3L (8/2006 ↔ S/N G004V02853E (LPG))
(8/2006 ↔ S/N G004V03165E (GASOLINE))

4-68 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (8/2006 ↔ S/N G004V02853E (LPG))
(8/2006 ↔ S/N G004V03165E (GASOLINE))

ITEM PART NO. DESCRIPTION QTY

2090887 Wire Harness ...................................................................................................... 1
1 1608857 Clip ................................................................................................................. 1
2 1509888 Clip ................................................................................................................. 3
3 ..... Connector Assembly (To Backup Alarm Harness) ......................................... 1
3 1490242 Connector ................................................................................................... 1
3 1490243 Connector ................................................................................................... 1
3 1330438 Terminal (Socket) ....................................................................................... 2
4 1626727 Connector (End Cap) ..................................................................................... 1
5 ..... Connector Assembly (Coolant Level) ............................................................. 1
5 1329152 Plug ............................................................................................................ 1
5 1329151 Terminal ..................................................................................................... 1
5 1330281 Terminal ..................................................................................................... 2
5 1402888 Seal ............................................................................................................ 2
6 ..... Connector Assembly (End Cap) ..................................................................... 1
6 1329150 Connector ................................................................................................... 1
6 1329151 Terminal ..................................................................................................... 1
6 1327164 Seal ............................................................................................................ 2
7 ..... Connector Assembly (Key Switch and Alternate Horn Button) ...................... 2
7 1490242 Connector ................................................................................................... 1
7 1490243 Connector ................................................................................................... 1
7 1330438 Terminal (Socket) ....................................................................................... 2
8 ..... Connector Assembly (Bus Terminal 2) ........................................................... 1
8 1489656 Connector (4-Way) ..................................................................................... 1
8 1489657 Connector ................................................................................................... 1
8 1330438 Terminal (Socket) ....................................................................................... 4
9 ..... Connector Assembly (To Seat Harness) ........................................................ 1
9 1541991 Connector ................................................................................................... 1
9 1541992 Connector ................................................................................................... 1
9 1463139 Terminal ..................................................................................................... 8
10 1402815 Clip ................................................................................................................. 2
11 1525577 Connector (With Resistor) (End Cap) ............................................................. 1
12 ..... Connector Assembly (Power Distribution Module) ......................................... 1
12 1521186 Connector ................................................................................................... 1
12 1521188 Lock ............................................................................................................ 1
12 1323579 Seal ............................................................................................................ 7
12 1327164 Seal ............................................................................................................ 1
12 1521989 Terminal ..................................................................................................... 7
13 ..... Connector Assembly (Power Distribution Module) ......................................... 1
13 1521183 Connector ................................................................................................... 1
13 1521188 Lock ............................................................................................................ 1
13 1323579 Seal ............................................................................................................ 7
13 1327164 Seal ............................................................................................................ 1
13 1330281 Terminal ..................................................................................................... 4
13 1521989 Terminal ..................................................................................................... 3
14 ..... Connector Assembly (Power Distribution Module) ......................................... 1
14 1521184 Connector ................................................................................................... 1
14 1521188 Lock ............................................................................................................ 1
14 1323579 Seal ............................................................................................................ 5
14 1327164 Seal ............................................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 4-69

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (8/2006 ↔ S/N G004V02853E (LPG))
(8/2006 ↔ S/N G004V03165E (GASOLINE))

ITEM PART NO. DESCRIPTION QTY

14 1330281 Terminal ..................................................................................................... 6
14 1521989 Terminal ..................................................................................................... 1
14 1402888 Seal ............................................................................................................ 2
15 ..... Connector Assembly ...................................................................................... 1
15 1521185 Connector ................................................................................................... 1
15 1521188 Lock ............................................................................................................ 1
15 1323579 Seal ............................................................................................................ 8
15 1330281 Terminal ..................................................................................................... 5
15 1521989 Terminal ..................................................................................................... 3
16 1500899 Clip ................................................................................................................. 1
17 ..... Connector Assembly (To Transmission Harness) .......................................... 1
17 1525567 Connector ................................................................................................... 1
17 1529046 Connector ................................................................................................... 1
17 1463139 Terminal ..................................................................................................... 11
17 1484377 Plug ............................................................................................................ 1
18 ..... Connector Assembly (To Transmission Harness) .......................................... 1
18 1531973 Connector ................................................................................................... 1
18 1531974 Connector ................................................................................................... 1
18 1463139 Terminal ..................................................................................................... 6
19 ..... Connector Assembly (To Engine Harness) .................................................... 1
19 1531501 Connector ................................................................................................... 1
19 1330438 Terminal (Socket) ....................................................................................... 15
19 1463139 Terminal ..................................................................................................... 6
19 1484377 Plug ............................................................................................................ 4
19 1554359 Terminal ..................................................................................................... 4
20 ..... Connector Assembly (To Lights and Cab Harness) ....................................... 1
20 1514597 Connector ................................................................................................... 1
20 1514602 Connector ................................................................................................... 1
20 1330439 Plug ............................................................................................................ 4
20 1514603 Connector ................................................................................................... 1
20 1554359 Terminal ..................................................................................................... 4
21 ..... Connector Assembly (End Cap) ..................................................................... 1
22 ..... Connector Assembly (Accessory 1) ............................................................... 1
22 1545202 Connector ................................................................................................... 1
22 1546697 Connector ................................................................................................... 1
22 1554359 Terminal ..................................................................................................... 2
23 ..... Connector Assembly (End Cap) ..................................................................... 1
23 1480187 Connector ................................................................................................... 1
23 1330439 Plug ............................................................................................................ 2
24 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
24 1525570 Connector ................................................................................................... 1
24 1530037 Connector ................................................................................................... 1
24 1463139 Terminal ..................................................................................................... 8
24 1484377 Plug ............................................................................................................ 4
25 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
25 1525568 Connector ................................................................................................... 1
25 1530037 Connector ................................................................................................... 1
25 1463139 Terminal ..................................................................................................... 7
25 1484377 Plug ............................................................................................................ 5

4-70 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (8/2006 ↔ S/N G004V02853E (LPG))
(8/2006 ↔ S/N G004V03165E (GASOLINE))

ITEM PART NO. DESCRIPTION QTY

26 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
26 1525567 Connector ................................................................................................... 1
26 1530037 Connector ................................................................................................... 1
26 1463139 Terminal ..................................................................................................... 9
26 1484377 Plug ............................................................................................................ 3
27 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
27 1525563 Connector ................................................................................................... 1
27 1500913 Connector ................................................................................................... 1
27 1330438 Terminal (Socket) ....................................................................................... 8
27 1363886 Terminal (Socket) ....................................................................................... 4
28 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
28 1489655 Connector (4 Way) ..................................................................................... 1
28 1330416 Connector ................................................................................................... 1
28 1330437 Terminal (Pin) ............................................................................................. 4
29 ..... Connector Assembly (To Cowl Harness) ....................................................... 1
29 1493428 Connector (12-Way) ................................................................................... 1
29 1500913 Connector ................................................................................................... 1
29 1330438 Terminal (Socket) ....................................................................................... 9
29 1484377 Plug ............................................................................................................ 3
30 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
30 1525567 Connector ................................................................................................... 1
30 1529046 Connector ................................................................................................... 1
30 1463139 Terminal ..................................................................................................... 3
30 1484377 Plug ............................................................................................................ 9
31 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
31 1525569 Connector ................................................................................................... 1
31 1529046 Connector ................................................................................................... 1
31 1463139 Terminal ..................................................................................................... 3
31 1484377 Plug ............................................................................................................ 9
32 ..... Connector Assembly (To Horn) ...................................................................... 1
32 1476064 Connector ................................................................................................... 1
32 1476109 Connector Lock .......................................................................................... 1
32 1330356 Seal ............................................................................................................ 2
32 1330355 Terminal ..................................................................................................... 3
32 1476108 Wire Seal .................................................................................................... 1
33 1534282 Clip ................................................................................................................. 1
34 ..... Connector Assembly (To Hydraulic Filter) ...................................................... 1
34 1329152 Plug ............................................................................................................ 1
34 1329151 Terminal ..................................................................................................... 1
34 1330281 Terminal ..................................................................................................... 2
34 1402888 Seal ............................................................................................................ 2
35 ..... Connector Assembly (End Cap) ..................................................................... 1
35 1329150 Connector ................................................................................................... 1
35 1329151 Terminal ..................................................................................................... 1
35 1327164 Seal ............................................................................................................ 2
36 ..... Connector Assembly (Accessory 2) ............................................................... 1
36 1514602 Connector ................................................................................................... 1
36 1514603 Connector ................................................................................................... 1
36 1330439 Plug ............................................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 4-71

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (8/2006 ↔ S/N G004V02853E (LPG))
(8/2006 ↔ S/N G004V03165E (GASOLINE))

ITEM PART NO. DESCRIPTION QTY

36 1554359 Terminal ..................................................................................................... 3
37 ..... Connector Assembly (End Cap) ..................................................................... 1
37 1514597 Connector ................................................................................................... 1
37 1330439 Plug ............................................................................................................ 4
38 1626727 Connector (End Cap) ..................................................................................... 2

4-72 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-73

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-29)

RIGHT HAND CHASSIS — GM 4.3L (S/N G004V02854E ↔ S/N G004V04328G (LPG))
(S/N G004V03166E ↔ S/N G004V04328G (GASOLINE))

4-74 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (S/N G004V02854E ↔ S/N G004V04328G (LPG))
(S/N G004V03166E ↔ S/N G004V04328G (GASOLINE))

ITEM PART NO. DESCRIPTION QTY

2097392 Wire Harness ...................................................................................................... 1
1 1608857 Clip ................................................................................................................. 1
2 1509888 Clip ................................................................................................................. 3
3 ..... Connector Assembly (To Backup Alarm Harness) ......................................... 1
3 1490242 Connector ................................................................................................... 1
3 1490243 Connector ................................................................................................... 1
3 1330438 Terminal (Socket) ....................................................................................... 2
4 1626727 Connector (End Cap) ..................................................................................... 1
5 ..... Connector Assembly (Coolant Level) ............................................................. 1
5 1329152 Plug ............................................................................................................ 1
5 1329151 Terminal ..................................................................................................... 1
5 1330281 Terminal ..................................................................................................... 2
5 1402888 Seal ............................................................................................................ 2
6 ..... Connector Assembly (End Cap) ..................................................................... 1
6 1329150 Connector ................................................................................................... 1
6 1329151 Terminal ..................................................................................................... 1
6 1327164 Seal ............................................................................................................ 2
7 ..... Connector Assembly (Key Switch and Alternate Horn Button) ...................... 2
7 1490242 Connector ................................................................................................... 1
7 1490243 Connector ................................................................................................... 1
7 1330438 Terminal (Socket) ....................................................................................... 2
8 ..... Connector Assembly (Bus Terminal 2) ........................................................... 1
8 1489656 Connector (4-Way) ..................................................................................... 1
8 1489657 Connector ................................................................................................... 1
8 1330438 Terminal (Socket) ....................................................................................... 4
9 ..... Connector Assembly (To Seat Harness) ........................................................ 1
9 1541991 Connector ................................................................................................... 1
9 1541992 Connector ................................................................................................... 1
9 1463139 Terminal ..................................................................................................... 8
10 1402815 Clip ................................................................................................................. 2
11 1525577 Connector (With Resistor) (End Cap) ............................................................. 1
12 ..... Connector Assembly (Power Distribution Module) ......................................... 1
12 1521186 Connector ................................................................................................... 1
12 1521188 Lock ............................................................................................................ 1
12 1323579 Seal ............................................................................................................ 7
12 1327164 Seal ............................................................................................................ 1
12 1521989 Terminal ..................................................................................................... 7
13 ..... Connector Assembly (Power Distribution Module) ......................................... 1
13 1521183 Connector ................................................................................................... 1
13 1521188 Lock ............................................................................................................ 1
13 1323579 Seal ............................................................................................................ 7
13 1327164 Seal ............................................................................................................ 1
13 1330281 Terminal ..................................................................................................... 4
13 1521989 Terminal ..................................................................................................... 3
14 ..... Connector Assembly (Power Distribution Module) ......................................... 1
14 1521184 Connector ................................................................................................... 1
14 1521188 Lock ............................................................................................................ 1
14 1323579 Seal ............................................................................................................ 5
14 1327164 Seal ............................................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 4-75

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (S/N G004V02854E ↔ S/N G004V04328G (LPG))
(S/N G004V03166E ↔ S/N G004V04328G (GASOLINE))

ITEM PART NO. DESCRIPTION QTY

14 1330281 Terminal ..................................................................................................... 6
14 1521989 Terminal ..................................................................................................... 1
14 1402888 Seal ............................................................................................................ 2
15 ..... Connector Assembly ...................................................................................... 1
15 1521185 Connector ................................................................................................... 1
15 1521188 Lock ............................................................................................................ 1
15 1323579 Seal ............................................................................................................ 8
15 1330281 Terminal ..................................................................................................... 5
15 1521989 Terminal ..................................................................................................... 3
16 1500899 Clip ................................................................................................................. 1
17 ..... Connector Assembly (To Transmission Harness) .......................................... 1
17 1525567 Connector ................................................................................................... 1
17 1529046 Connector ................................................................................................... 1
17 1463139 Terminal ..................................................................................................... 11
17 1484377 Plug ............................................................................................................ 1
18 ..... Connector Assembly (To Transmission Harness) .......................................... 1
18 1531973 Connector ................................................................................................... 1
18 1531974 Connector ................................................................................................... 1
18 1463139 Terminal ..................................................................................................... 6
19 ..... Connector Assembly (To Engine Harness) .................................................... 1
19 1514602 Connector ................................................................................................... 1
19 1514603 Connector ................................................................................................... 1
19 1554359 Terminal ..................................................................................................... 4
20 ..... Connector Assembly (To Engine Harness) .................................................... 1
20 1502625 Connector ................................................................................................... 1
20 1502626 Connector ................................................................................................... 1
20 1330438 Terminal (Socket) ....................................................................................... 7
20 1484377 Plug ............................................................................................................ 1
21 ..... Connector Assembly (To Engine Harness) .................................................... 1
21 1541991 Connector ................................................................................................... 1
21 1541992 Connector ................................................................................................... 1
21 1463139 Terminal ..................................................................................................... 8
22 ..... Connector Assembly (To Lights and Cab Harness) ....................................... 1
22 1514597 Connector ................................................................................................... 1
22 1514602 Connector ................................................................................................... 1
22 1330439 Plug ............................................................................................................ 4
22 1514603 Connector ................................................................................................... 1
22 1554359 Terminal ..................................................................................................... 4
23 ..... Connector Assembly (End Cap) ..................................................................... 1
24 ..... Connector Assembly (Accessory 1) ............................................................... 1
24 1545202 Connector ................................................................................................... 1
24 1546697 Connector ................................................................................................... 1
24 1554359 Terminal ..................................................................................................... 2
25 ..... Connector Assembly (End Cap) ..................................................................... 1
25 1480187 Connector ................................................................................................... 1
25 1330439 Plug ............................................................................................................ 2
26 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
26 1525570 Connector ................................................................................................... 1
26 1530037 Connector ................................................................................................... 1

4-76 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (S/N G004V02854E ↔ S/N G004V04328G (LPG))
(S/N G004V03166E ↔ S/N G004V04328G (GASOLINE))

ITEM PART NO. DESCRIPTION QTY

26 1463139 Terminal ..................................................................................................... 8
26 1484377 Plug ............................................................................................................ 4
27 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
27 1525568 Connector ................................................................................................... 1
27 1530037 Connector ................................................................................................... 1
27 1463139 Terminal ..................................................................................................... 7
27 1484377 Plug ............................................................................................................ 5
28 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
28 1525567 Connector ................................................................................................... 1
28 1530037 Connector ................................................................................................... 1
28 1463139 Terminal ..................................................................................................... 9
28 1484377 Plug ............................................................................................................ 3
29 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
29 1525563 Connector ................................................................................................... 1
29 1500913 Connector ................................................................................................... 1
29 1330438 Terminal (Socket) ....................................................................................... 8
29 1363886 Terminal (Socket) ....................................................................................... 4
30 ..... Connector Assembly (To Cowl Harness) ....................................................... 1
30 1489655 Connector (4 Way) ..................................................................................... 1
30 1330416 Connector ................................................................................................... 1
30 1330437 Terminal (Pin) ............................................................................................. 4
31 ..... Connector Assembly (To Cowl Harness) ....................................................... 1
31 1493428 Connector (12-Way) ................................................................................... 1
31 1500913 Connector ................................................................................................... 1
31 1330438 Terminal (Socket) ....................................................................................... 9
31 1484377 Plug ............................................................................................................ 3
32 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
32 1525567 Connector ................................................................................................... 1
32 1529046 Connector ................................................................................................... 1
32 1463139 Terminal ..................................................................................................... 3
32 1484377 Plug ............................................................................................................ 9
33 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
33 1525569 Connector ................................................................................................... 1
33 1529046 Connector ................................................................................................... 1
33 1463139 Terminal ..................................................................................................... 3
33 1484377 Plug ............................................................................................................ 9
34 ..... Connector Assembly (To Horn) ...................................................................... 1
34 1476064 Connector ................................................................................................... 1
34 1476109 Connector Lock .......................................................................................... 1
34 1330356 Seal ............................................................................................................ 2
34 1330355 Terminal ..................................................................................................... 3
34 1476108 Wire Seal .................................................................................................... 1
35 1534282 Clip ................................................................................................................. 1
36 ..... Connector Assembly (To Hydraulic Filter) ...................................................... 1
36 1329152 Plug ............................................................................................................ 1
36 1329151 Terminal ..................................................................................................... 1
36 1330281 Terminal ..................................................................................................... 2
36 1402888 Seal ............................................................................................................ 2
37 ..... Connector Assembly (End Cap) ..................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-77

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (S/N G004V02854E ↔ S/N G004V04328G (LPG))
(S/N G004V03166E ↔ S/N G004V04328G (GASOLINE))

ITEM PART NO. DESCRIPTION QTY

37 1329150 Connector ................................................................................................... 1
37 1329151 Terminal ..................................................................................................... 1
37 1327164 Seal ............................................................................................................ 2
38 ..... Connector Assembly (Accessory 2) ............................................................... 1
38 1514602 Connector ................................................................................................... 1
38 1514603 Connector ................................................................................................... 1
38 1330439 Plug ............................................................................................................ 1
38 1554359 Terminal ..................................................................................................... 3
39 ..... Connector Assembly (End Cap) ..................................................................... 1
39 1514597 Connector ................................................................................................... 1
39 1330439 Plug ............................................................................................................ 4
40 1626727 Connector (End Cap) ..................................................................................... 2

4-78 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-79

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-30)

RIGHT HAND CHASSIS — GM 4.3L (S/N G004V04329G ↔ PENDING PER ECN 10551437)

4-80 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (S/N G004V04329G ↔ PENDING PER ECN 10551437)

ITEM PART NO. DESCRIPTION QTY

2105635 Wire Harness ...................................................................................................... 1
1 1509890 Clip ................................................................................................................. 1
2 1509888 Clip ................................................................................................................. 3
3 ..... Connector Assembly (To Backup Alarm Harness) ......................................... 1
3 1490242 Connector ................................................................................................... 1
3 1490243 Connector ................................................................................................... 1
3 1330438 Terminal (Socket) ....................................................................................... 2
4 1626727 Connector (End Cap) ..................................................................................... 1
5 ..... Connector Assembly (Coolant Level) ............................................................. 1
5 1329152 Plug ............................................................................................................ 1
5 1329151 Terminal ..................................................................................................... 1
5 1330281 Terminal ..................................................................................................... 2
5 1402888 Seal ............................................................................................................ 2
6 ..... Connector Assembly (End Cap) ..................................................................... 1
6 1329150 Connector ................................................................................................... 1
6 1329151 Terminal ..................................................................................................... 1
6 1327164 Seal ............................................................................................................ 2
7 ..... Connector Assembly (Key Switch and Alternate Horn Button) ...................... 2
7 1490242 Connector ................................................................................................... 1
7 1490243 Connector ................................................................................................... 1
7 1330438 Terminal (Socket) ....................................................................................... 2
8 ..... Connector Assembly (Bus Terminal 2) ........................................................... 1
8 1489656 Connector (4-Way) ..................................................................................... 1
8 1489657 Connector ................................................................................................... 1
8 1330438 Terminal (Socket) ....................................................................................... 4
9 ..... Connector Assembly (To Seat Harness) ........................................................ 1
9 1541991 Connector ................................................................................................... 1
9 1541992 Connector ................................................................................................... 1
9 1463139 Terminal ..................................................................................................... 8
10 1402815 Clip ................................................................................................................. 2
11 1525577 Connector (With Resistor) (End Cap) ............................................................. 1
12 ..... Connector Assembly (Power Distribution Module) ......................................... 1
12 1521186 Connector ................................................................................................... 1
12 1521188 Lock ............................................................................................................ 1
12 1323579 Seal ............................................................................................................ 7
12 1327164 Seal ............................................................................................................ 1
12 1521989 Terminal ..................................................................................................... 7
13 ..... Connector Assembly (Power Distribution Module) ......................................... 1
13 1521183 Connector ................................................................................................... 1
13 1521188 Lock ............................................................................................................ 1
13 1323579 Seal ............................................................................................................ 7
13 1327164 Seal ............................................................................................................ 1
13 1330281 Terminal ..................................................................................................... 4
13 1521989 Terminal ..................................................................................................... 3
14 ..... Connector Assembly (Power Distribution Module) ......................................... 1
14 1521184 Connector ................................................................................................... 1
14 1521188 Lock ............................................................................................................ 1
14 1323579 Seal ............................................................................................................ 5
14 1327164 Seal ............................................................................................................ 1
14 1330281 Terminal ..................................................................................................... 6

©2011 HYSTER COMPANY See Service Manual 4-81

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (S/N G004V04329G ↔ PENDING PER ECN 10551437)

ITEM PART NO. DESCRIPTION QTY

14 1521989 Terminal ..................................................................................................... 1
14 1402888 Seal ............................................................................................................ 2
15 ..... Connector Assembly ...................................................................................... 1
15 1521185 Connector ................................................................................................... 1
15 1521188 Lock ............................................................................................................ 1
15 1323579 Seal ............................................................................................................ 8
15 1330281 Terminal ..................................................................................................... 5
15 1521989 Terminal ..................................................................................................... 3
16 1500899 Clip ................................................................................................................. 1
17 ..... Connector Assembly (To Transmission Harness) .......................................... 1
17 1525567 Connector ................................................................................................... 1
17 1529046 Connector ................................................................................................... 1
17 1463139 Terminal ..................................................................................................... 11
17 1484377 Plug ............................................................................................................ 1
18 ..... Connector Assembly (To Transmission Harness) .......................................... 1
18 1531973 Connector ................................................................................................... 1
18 1531974 Connector ................................................................................................... 1
18 1463139 Terminal ..................................................................................................... 6
19 ..... Connector Assembly (To Engine Harness) .................................................... 1
19 1514602 Connector ................................................................................................... 1
19 1514603 Connector ................................................................................................... 1
19 1554359 Terminal ..................................................................................................... 4
20 ..... Connector Assembly (To Engine Harness) .................................................... 1
20 1502625 Connector ................................................................................................... 1
20 1502626 Connector ................................................................................................... 1
20 1330438 Terminal (Socket) ....................................................................................... 7
20 1484377 Plug ............................................................................................................ 1
21 ..... Connector Assembly (To Engine Harness) .................................................... 1
21 1541991 Connector ................................................................................................... 1
21 1541992 Connector ................................................................................................... 1
21 1463139 Terminal ..................................................................................................... 8
22 ..... Connector Assembly (To Lights and Cab Harness) ....................................... 1
22 1514602 Connector ................................................................................................... 1
22 1514603 Connector ................................................................................................... 1
22 1554359 Terminal ..................................................................................................... 4
23 ..... Connector Assembly (End Cap) ..................................................................... 1
23 1514597 Connector ................................................................................................... 1
23 1330439 Plug ............................................................................................................ 4
24 ..... Connector Assembly (Accessory 1) ............................................................... 1
24 1545202 Connector ................................................................................................... 1
24 1546697 Connector ................................................................................................... 1
24 1554359 Terminal ..................................................................................................... 2
25 ..... Connector Assembly (End Cap) ..................................................................... 1
25 1480187 Connector ................................................................................................... 1
25 1330439 Plug ............................................................................................................ 2
26 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
26 1525570 Connector ................................................................................................... 1
26 1530037 Connector ................................................................................................... 1
26 1463139 Terminal ..................................................................................................... 8
26 1484377 Plug ............................................................................................................ 4

4-82 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (S/N G004V04329G ↔ PENDING PER ECN 10551437)

ITEM PART NO. DESCRIPTION QTY

27 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
27 1525568 Connector ................................................................................................... 1
27 1530037 Connector ................................................................................................... 1
27 1463139 Terminal ..................................................................................................... 7
27 1484377 Plug ............................................................................................................ 5
28 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
28 1525567 Connector ................................................................................................... 1
28 1530037 Connector ................................................................................................... 1
28 1463139 Terminal ..................................................................................................... 9
28 1484377 Plug ............................................................................................................ 3
29 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
29 1525563 Connector ................................................................................................... 1
29 1500913 Connector ................................................................................................... 1
29 1330438 Terminal (Socket) ....................................................................................... 8
29 1363886 Terminal (Socket) ....................................................................................... 4
30 ..... Connector Assembly (To Cowl Harness) ....................................................... 1
30 1489655 Connector (4 Way) ..................................................................................... 1
30 1330416 Connector ................................................................................................... 1
30 1330437 Terminal (Pin) ............................................................................................. 4
31 ..... Connector Assembly (To Cowl Harness) ....................................................... 1
31 1493428 Connector (12-Way) ................................................................................... 1
31 1500913 Connector ................................................................................................... 1
31 1330438 Terminal (Socket) ....................................................................................... 9
31 1484377 Plug ............................................................................................................ 3
32 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
32 1525567 Connector ................................................................................................... 1
32 1529046 Connector ................................................................................................... 1
32 1463139 Terminal ..................................................................................................... 3
32 1484377 Plug ............................................................................................................ 9
33 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
33 1525569 Connector ................................................................................................... 1
33 1529046 Connector ................................................................................................... 1
33 1463139 Terminal ..................................................................................................... 3
33 1484377 Plug ............................................................................................................ 9
34 ..... Connector Assembly (To Horn) ...................................................................... 1
34 1476064 Connector ................................................................................................... 1
34 1476109 Connector Lock .......................................................................................... 1
34 1330356 Seal ............................................................................................................ 2
34 1330355 Terminal ..................................................................................................... 3
34 1476108 Wire Seal .................................................................................................... 1
35 1534282 Clip ................................................................................................................. 1
36 ..... Connector Assembly (To Hydraulic Filter) ...................................................... 1
36 1329152 Plug ............................................................................................................ 1
36 1329151 Terminal ..................................................................................................... 1
36 1330281 Terminal ..................................................................................................... 2
36 1402888 Seal ............................................................................................................ 2
37 ..... Connector Assembly (End Cap) ..................................................................... 1
37 1329150 Connector ................................................................................................... 1
37 1329151 Terminal ..................................................................................................... 1
37 1327164 Seal ............................................................................................................ 2

©2011 HYSTER COMPANY See Service Manual 4-83

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (S/N G004V04329G ↔ PENDING PER ECN 10551437)

ITEM PART NO. DESCRIPTION QTY

38 ..... Connector Assembly (Accessory 2) ............................................................... 1
38 1514602 Connector ................................................................................................... 1
38 1514603 Connector ................................................................................................... 1
38 1330439 Plug ............................................................................................................ 1
38 1554359 Terminal ..................................................................................................... 3
39 ..... Connector Assembly (End Cap) ..................................................................... 1
39 1514597 Connector ................................................................................................... 1
39 1330439 Plug ............................................................................................................ 4
40 1626727 Connector (End Cap) ..................................................................................... 2

4-84 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-85

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-31)

RIGHT HAND CHASSIS — GM 4.3L (PENDING PER ECN 10551437 →)

4-86 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (PENDING PER ECN 10551437 →)

ITEM PART NO. DESCRIPTION QTY

4606204 Wire Harness ..................................................................................................... 1
1 ..... Connector Assembly (VSM) ........................................................................ 1
1 1525567 Connector ................................................................................................. 1
1 1484377 Plug ........................................................................................................... 9
1 1463139 Terminal .................................................................................................... 3
1 1529046 Connector (Secondary Lock) .................................................................. 1
2 ..... Connector Assembly (VSM) ........................................................................ 1
2 1525569 Connector ................................................................................................... 1
2 1484377 Plug ........................................................................................................... 9
2 1463139 Terminal .................................................................................................... 3
2 1529046 Connector (Secondary Lock) .................................................................. 1
3 ..... Connector Assembly (Horn) ........................................................................ 1
3 1476064 Connector ................................................................................................... 1
3 1330355 Terminal .................................................................................................... 3
3 1330356 Seal ............................................................................................................ 2
3 1476108 Wire Seal ................................................................................................... 1
3 1476109 Connector Lock (Secondary Lock) ......................................................... 1
4 1534282 Clip ................................................................................................................. 1
5 ..... Connector Assembly (Hydraulic Filter) ...................................................... 1
5 1329152 Plug ............................................................................................................ 1
5 1330281 Terminal ..................................................................................................... 2
5 1402888 Seal ............................................................................................................ 2
5 1329151 Terminal (Secondary Lock) ........................................................................ 1
6 ..... Connector Assembly (Endcap) ................................................................... 1
6 1327164 Seal ............................................................................................................ 2
6 1329151 Terminal (Secondary Lock) ........................................................................ 1
7 ..... Connector Assembly (ACC 2) ..................................................................... 1
7 1514602 Connector ................................................................................................... 1
7 1554359 Terminal ..................................................................................................... 3
7 1330439 Plug ............................................................................................................ 1
7 1514603 Connector (Secondary Lock) ..................................................................... 1
8 ..... Connector Assembly (ACC 1) ..................................................................... 1
8 1514597 Connector ................................................................................................. 1
8 1330439 Plug ............................................................................................................ 4
9 ..... Connector Assembly (Hood Switch/Key Switch) ...................................... 1
9 1490242 Connector ................................................................................................. 1
9 1330438 Terminal (Socket) ..................................................................................... 2
9 1490243 Connector (Secondary Lock) .................................................................. 1
10 ..... Connector Assembly (Endcap) ................................................................... 1
10 1626727 Connector ................................................................................................... 1
11 ..... Connector Assembly (Alternate Horn Button) .......................................... 1
11 1490242 Connector ................................................................................................. 1
11 1330438 Terminal (Socket) ..................................................................................... 2
11 1490243 Connector (Secondary Lock) .................................................................. 1
12 ..... Connector Assembly (Endcap) ................................................................... 1
12 1626727 Connector ................................................................................................... 1
13 ..... Connector Assembly (Bus Term 2) ............................................................ 1
13 1489656 Connector (4-Way) ................................................................................... 1
13 1330438 Terminal (Socket) ..................................................................................... 4
13 1489657 Connector (Secondary Lock) .................................................................. 1

©2011 HYSTER COMPANY See Service Manual 4-87

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (PENDING PER ECN 10551437 →)

ITEM PART NO. DESCRIPTION QTY

14 ..... Connector Assembly (Endcap) ................................................................... 1
14 1525577 Connector (With Resistor) ....................................................................... 1
15 1509890 Clip ................................................................................................................. 3
16 1509888 Clip ................................................................................................................. 6
17 ..... Connector Assembly (Backup Alarm) ........................................................ 1
17 1490242 Connector ................................................................................................. 1
17 1330438 Terminal (Socket) ..................................................................................... 2
17 1490243 Connector (Secondary Lock) .................................................................. 1
18 ..... Connector Assembly (Endcap) ................................................................... 1
18 1626727 Connector ................................................................................................... 1
19 ..... Connector Assembly (Coolant Level) ........................................................ 1
19 1329152 Plug ............................................................................................................ 1
19 1330281 Terminal ..................................................................................................... 2
19 1402888 Seal ............................................................................................................ 2
19 1329151 Terminal (Secondary Lock) ........................................................................ 1
20 ..... Connector Assembly (Endcap) ................................................................... 1
20 1329150 Connector ................................................................................................... 1
20 1327164 Seal ............................................................................................................ 2
20 1329151 Terminal (Secondary Lock) ........................................................................ 1
21 ..... Connector Assembly (Seat Harness) ......................................................... 1
21 1531973 Connector ................................................................................................... 1
21 1463139 Terminal .................................................................................................... 4
21 1484377 Plug ........................................................................................................... 2
21 1531974 Connector (Secondary Lock) ..................................................................... 1
22 ..... Connector Assembly (Endcap) ................................................................... 1
22 1541988 Connector ................................................................................................. 1
22 1484377 Plug ........................................................................................................... 8
23 ..... Connector Assembly (MLM Harness) ......................................................... 1
23 1541991 Connector ................................................................................................... 1
23 1463139 Terminal .................................................................................................... 5
23 1484377 Plug ........................................................................................................... 3
23 1541992 Connector (Secondary Lock) ..................................................................... 1
24 1402815 Clip ................................................................................................................. 2
25 ..... Connector Assembly (PDM) ........................................................................ 1
25 1521183 Connector ................................................................................................... 1
25 1521989 Terminal ..................................................................................................... 3
25 1330281 Terminal ..................................................................................................... 4
25 1327164 Seal ............................................................................................................ 1
25 1323579 Seal ............................................................................................................ 7
25 1521188 Lock (Secondary Lock) .............................................................................. 1
26 ..... Connector Assembly (PDM) ........................................................................ 1
26 1521186 Connector ................................................................................................... 1
26 1521989 Terminal ..................................................................................................... 7
26 1327164 Seal ............................................................................................................ 1
26 1323579 Seal ............................................................................................................ 7
26 1521188 Lock (Secondary Lock) .............................................................................. 1
27 ..... Connector Assembly (PDM) ........................................................................ 1
27 1521185 Connector ................................................................................................... 1
27 1330281 Terminal ..................................................................................................... 5
27 1521989 Terminal ..................................................................................................... 3

4-88 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (PENDING PER ECN 10551437 →)

ITEM PART NO. DESCRIPTION QTY

27 1323579 Seal ............................................................................................................ 8
27 1521188 Lock (Secondary Lock) .............................................................................. 1
28 ..... Connector Assembly (PDM) ........................................................................ 1
28 1521184 Connector ................................................................................................... 1
28 1327164 Seal ............................................................................................................ 1
28 1330281 Terminal ..................................................................................................... 6
28 1521989 Terminal ..................................................................................................... 1
28 1323579 Seal ............................................................................................................ 5
28 1402888 Seal ............................................................................................................ 2
28 1521188 Lock (Secondary Lock) .............................................................................. 1
29 ..... Connector Assembly (Hydraulic Temp) ..................................................... 1
29 1402868 Connector ................................................................................................. 1
29 1323576 Terminal .................................................................................................... 2
30 1500899 Clip ................................................................................................................. 1
31 ..... Connector Assembly (Transmission Harness) ......................................... 1
31 1525567 Connector ................................................................................................. 1
31 1463139 Terminal .................................................................................................... 12
31 1529046 Connector (Secondary Lock) .................................................................. 1
32 ..... Connector Assembly (Transmission Harness) ......................................... 1
32 1531973 Connector ................................................................................................... 1
32 1463139 Terminal .................................................................................................... 6
32 1531974 Connector (Secondary Lock) ..................................................................... 1
33 ..... Connector Assembly (Engine Harness) ..................................................... 1
33 1541991 Connector ................................................................................................... 1
33 1463139 Terminal .................................................................................................... 8
33 1541992 Connector (Secondary Lock) ..................................................................... 1
34 ..... Connector Assembly (Endcap) ................................................................... 1
34 1626727 Connector ................................................................................................... 1
35 ..... Connector Assembly (Hydraulic Solenoid) ............................................... 1
35 1490242 Connector ................................................................................................. 1
35 1330438 Terminal (Socket) ..................................................................................... 2
35 1490243 Connector (Secondary Lock) .................................................................. 1
36 ..... Connector Assembly (Engine Harness) ..................................................... 1
36 1502625 Connector ................................................................................................... 1
36 1330438 Terminal (Socket) ..................................................................................... 8
36 1484377 Plug ........................................................................................................... 1
36 1502626 Connector (Secondary Lock) ..................................................................... 1
37 ..... Connector Assembly (Engine Harness) ..................................................... 1
37 1514602 Connector ................................................................................................... 1
37 1554359 Terminal ..................................................................................................... 4
37 1514603 Connector (Secondary Lock) ..................................................................... 1
38 ..... Connector Assembly (Lights/Cab Harness) .............................................. 1
38 1514602 Connector ................................................................................................... 1
38 1554359 Terminal ..................................................................................................... 4
38 1514603 Connector (Secondary Lock) ..................................................................... 1
39 ..... Connector Assembly (Endcap) ................................................................... 1
39 1514597 Connector ................................................................................................. 1
39 1330439 Plug ............................................................................................................ 4
40 ..... Connector Assembly (ACC 1) ..................................................................... 1
40 1545202 Connector ................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-89

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
RIGHT HAND CHASSIS – GM 4.3L (PENDING PER ECN 10551437 →)

ITEM PART NO. DESCRIPTION QTY

40 1554359 Terminal ..................................................................................................... 2
40 1546697 Connector (Secondary Lock) ..................................................................... 1
41 ..... Connector Assembly (Endcap) ................................................................... 1
41 1480187 Connector ................................................................................................... 1
41 1330439 Plug ............................................................................................................ 2
42 ..... Connector Assembly (VSM) ........................................................................ 1
42 1525570 Connector ................................................................................................. 1
42 1463139 Terminal .................................................................................................... 9
42 1484377 Plug ........................................................................................................... 3
43 ..... Connector Assembly (VSM) ........................................................................ 1
43 1525569 Connector ................................................................................................... 1
43 1484377 Plug ........................................................................................................... 10
43 1463139 Terminal .................................................................................................... 2
43 1530037 Connector (Secondary Lock) ..................................................................... 1
44 ..... Connector Assembly (VSM) ........................................................................ 1
44 1525568 Connector ................................................................................................. 1
44 1463139 Terminal .................................................................................................... 7
44 1484377 Plug ........................................................................................................... 5
44 1530037 Connector (Secondary Lock) ..................................................................... 1
45 ..... Connector Assembly ................................................................................... 1
45 1525567 Connector ................................................................................................. 1
45 1463139 Terminal .................................................................................................... 9
45 1484377 Plug ........................................................................................................... 3
46 ..... Connector Assembly (VSM) ........................................................................ 1
46 1525563 Connector ................................................................................................... 1
46 1363886 Terminal (Socket) ..................................................................................... 4
46 1330438 Terminal (Socket) ..................................................................................... 8
46 1500913 Connector (Secondary Lock) .................................................................. 1
47 ..... Connector Assembly (Cowl Harness) ........................................................ 1
47 1489655 Connector (4 Way) ................................................................................... 1
47 1330437 Terminal (Pin) ........................................................................................... 4
47 1330416 Connector (Secondary Lock) .................................................................. 1
48 ..... Connector Assembly (Cowl Harness) ........................................................ 1
48 1493428 Connector (12-Way) ................................................................................... 1
48 1330438 Terminal (Socket) ..................................................................................... 10
48 1484377 Plug ........................................................................................................... 2
48 1500913 Connector (Secondary Lock) .................................................................. 1

4-90 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-91

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-32)

SEAT JUMPER (→ PENDING PER ECN 10551437)

4-92 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
SEAT JUMPER (→ PENDING PER ECN 10551437)

ITEM PART NO. DESCRIPTION QTY

4601500 Wire Harness ...................................................................................................... 1
1 ..... Connector Assembly (Seat Harness) ............................................................. 1
1 1531973 Connector ................................................................................................... 1
1 1531974 Connector (Lock) ........................................................................................ 1
1 1463139 Terminal (Pin) ............................................................................................. 4
1 1484377 Plug ............................................................................................................ 2
2 ..... Connector Assembly (MLM Harness) ............................................................ 1
2 1541991 Connector ................................................................................................... 1
2 1541992 Connector (Lock) ........................................................................................ 1
2 1463139 Terminal (Pin) ............................................................................................. 5
2 1484377 Plug ............................................................................................................ 3
3 ..... End Cap ......................................................................................................... 1
3 1541988 Connector ................................................................................................... 1
3 1484377 Plug ............................................................................................................ 8
4 1509890 Clip ................................................................................................................. 3
5 1699754 Conduit ........................................................................................................... AR
6 275495 Conduit ........................................................................................................... AR
7 ..... Connector Assembly (RH Chassis Harness) ................................................. 1
7 1541988 Connector ................................................................................................... 1
7 1541989 Connector (Lock) ........................................................................................ 1
7 1463138 Terminal (Pin) ............................................................................................. 8
8 1697181 Conduit ........................................................................................................... AR
9 ..... Connector Assembly (RH Chassis Harness) ................................................. 1
9 1493465 Connector ................................................................................................... 1
9 1330414 Connector (Secondary Lock) ..................................................................... 1
9 1330437 Terminal (Pin) ............................................................................................. 2
10 275493 Conduit ........................................................................................................... AR
11 ..... Connector Assembly (Alternate Horn Button) ................................................ 1
11 1490242 Connector ................................................................................................... 1
11 1490243 Connector (Lock) ........................................................................................ 1
11 1330438 Terminal (Socket) ....................................................................................... 2
12 1626727 Connector (End Cap) ..................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-93

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-33)

LEFT HAND CHASSIS — GM 4.3L, GASOLINE (→ S/N G004V04601H EXC. 04572)

4-94 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
LEFT HAND CHASSIS – GM 4.3L, GASOLINE (→ S/N G004V04601H EXC. 04572)

ITEM PART NO. DESCRIPTION QTY

2077809 Wire Harness (LH Chassis) ................................................................................ 1
1 ..... Connector Assembly (Air Restriction) ............................................................ 1
1 1465469 Connector ................................................................................................... 1
1 1402888 Seal ............................................................................................................ 2
1 1323578 Terminal ..................................................................................................... 2
2 ..... End Cap (Air Restriction Cap) ........................................................................ 1
2 1465468 Connector ................................................................................................... 1
2 1327164 Seal ............................................................................................................ 3
3 ..... Connector Assembly (Latch Relay) ................................................................ 1
3 1461744 Connector Body ......................................................................................... 1
3 1327164 Seal ............................................................................................................ 3
3 1323579 Seal ............................................................................................................ 4
3 1402912 Terminal ..................................................................................................... 4
3 1498483 Sealant ....................................................................................................... AR
4 ..... Latch Relay Assembly .................................................................................... 1
4 1654578 Relay (Latch) .............................................................................................. 1
4 1654579 Clip (Relay) ................................................................................................ 1
5 ..... Connector Assembly (Fuel Level) .................................................................. 1
5 1476077 Connector ................................................................................................... 1
5 1323576 Terminal ..................................................................................................... 2
6 ..... Connector Assembly (Fuel Pump) ................................................................. 1
6 1519611 Connector ................................................................................................... 1
6 1323576 Terminal ..................................................................................................... 2
7 ..... Connector Assembly (To Engine Harness) .................................................... 1
7 1527273 Connector ................................................................................................... 1
7 1402926 Terminal ..................................................................................................... 3
7 1402927 Terminal ..................................................................................................... 5
7 1507571 Seal ............................................................................................................ 5
7 1402929 Wire Seal .................................................................................................... 3
7 1527305 Connector Lock .......................................................................................... 1
8 1509888 Clip ................................................................................................................. 1

©2011 HYSTER COMPANY See Service Manual 4-95

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-34)

LEFT HAND CHASSIS — GM 4.3L GASOLINE (SERIES 2010) (S/N G004V04608H → INC. 04572)

4-96 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
LEFT HAND CHASSIS – GM 4.3L GASOLINE (SERIES 2010) (S/N G004V04608H → INC. 04572)

ITEM PART NO. DESCRIPTION QTY

4604532 Wire Harness (LH Chassis) (Left Hand Chassis) ........................................... 1
1 ..... Connector Assembly (To Engine Harness) ............................................... 1
1 4006330 Connector ................................................................................................... 1
1 1527305 Connector Lock ........................................................................................ 1
1 1402926 Terminal .................................................................................................... 3
1 1402927 Terminal .................................................................................................... 9
1 1402929 Wire Seal ................................................................................................... 3
1 1507571 Seal ............................................................................................................ 9
2 1509888 Clip ................................................................................................................. 2
3 ..... Connector Assembly (Air Restriction Sensor) .......................................... 1
3 1465469 Connector ................................................................................................. 1
3 1323578 Terminal .................................................................................................... 2
3 1402888 Seal ............................................................................................................ 2
4 ..... Connector Assembly (Air Restriction Cap) ............................................... 1
4 1465468 Connector ................................................................................................. 1
4 1327164 Seal ............................................................................................................ 2
5 ..... Connector Assembly (Rear Oxygen Sensor) ............................................. 1
5 1498424 Housing ..................................................................................................... 1
5 1650797 Lock ........................................................................................................... 1
5 1482666 Connector Body (Male) ............................................................................ 4
5 1476108 Wire Seal ................................................................................................... 4
6 ..... Connector Assembly (Latch Relay) ............................................................ 1
6 1461744 Connector Body ....................................................................................... 1
6 1503088 Lock ........................................................................................................... 1
6 1327164 Seal ............................................................................................................ 1
6 1402912 Terminal .................................................................................................... 4
6 1323579 Seal ............................................................................................................ 4
7 ..... Connector Assembly (Relay) ...................................................................... 1
7 1461743 Relay .......................................................................................................... 1
8 ..... Connector Assembly (Fuel Level) .............................................................. 1
8 1476077 Connector ................................................................................................. 1
8 1323576 Terminal .................................................................................................... 2
9 ..... Connector Assembly (Fuel Pump) .............................................................. 1
9 1519611 Connector ................................................................................................. 1
9 1323576 Terminal .................................................................................................... 2

©2011 HYSTER COMPANY See Service Manual 4-97

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-35)

LEFT HAND CHASSIS — GM 4.3L, LPG (→ S/N G004V04607H EXC. 04572)

ITEM PART NO. DESCRIPTION QTY

2077810 Wire Harness (LH Chassis) ................................................................................ 1
1 ..... Connector Assembly (Air Restriction) ............................................................ 1
1 1465469 Connector ................................................................................................... 1
1 1323578 Terminal ..................................................................................................... 2
1 1402888 Seal ............................................................................................................ 2
2 ..... End Cap Assembly (Air Restriction Cap) ....................................................... 1
2 1465468 Connector ................................................................................................... 1
2 1327164 Seal ............................................................................................................ 1
3 ..... Connector Assembly (LPG Lockoff) ............................................................... 1
3 1599337 Connector ................................................................................................... 1
3 1561146 Terminal ..................................................................................................... 2
4 ..... Connector Assembly (Low LPG Switch) ........................................................ 1
4 1402888 Seal ............................................................................................................ 2
4 1329152 Plug ............................................................................................................ 1
4 1329148 Terminal ..................................................................................................... 2
5 ..... Connector Assembly (Latch Relay) ................................................................ 1
5 1461744 Connector Body ......................................................................................... 1
5 1327164 Seal ............................................................................................................ 1
5 1323579 Seal ............................................................................................................ 4
5 1402912 Terminal ..................................................................................................... 4
5 1498483 Sealant ....................................................................................................... AR
6 ..... Connector Assembly (To Engine Wire Harness) ............................................ 1
6 1527273 Connector ................................................................................................... 1
6 1402926 Terminal ..................................................................................................... 3
6 1402927 Terminal ..................................................................................................... 5

4-98 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ITEM PART NO. DESCRIPTION QTY

6 1507571 Seal ............................................................................................................ 5
6 1402929 Wire Seal .................................................................................................... 3
6 1527305 Connector Lock .......................................................................................... 1
7 1509888 Clip ................................................................................................................. 1
8 ..... Latch Relay Assembly .................................................................................... 1
8 1654578 Relay (Latch) .............................................................................................. 1
8 1654579 Clip (Relay) ................................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 4-99

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-36)

LEFT HAND CHASSIS — GM 4.3L LPG (2010 SERIES)(WITH PREMIUM LOW FUEL SENSOR)
(S/N G004V04608H → INC. 04572)

4-100 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
LEFT HAND CHASSIS – GM 4.3L LPG (2010 SERIES)(WITH PREMIUM LOW FUEL SENSOR)
(S/N G004V04608H → INC. 04572)

ITEM PART NO. DESCRIPTION QTY

4604390 Wire Harness (LH Chassis) (Left Hand Chassis) ............................................... 1
1 ..... Connector Assembly (To Engine Harness) .................................................... 1
1 4006330 Connector ................................................................................................... 1
1 1527305 Connector Lock .......................................................................................... 1
1 1402926 Terminal ..................................................................................................... 3
1 1402927 Terminal ..................................................................................................... 9
1 1402929 Wire Seal .................................................................................................... 3
1 1507571 Seal ............................................................................................................ 9
2 1509888 Clip ................................................................................................................. 2
3 ..... Connector Assembly (LPG Lockoff) ............................................................... 1
3 1599337 Connector ................................................................................................... 1
3 1623057 Terminal ..................................................................................................... 2
4 ..... Connector Assembly (Rear Oxygen Sensor) ................................................. 1
4 1498424 Housing ...................................................................................................... 1
4 1650797 Lock ............................................................................................................ 1
4 1482666 Connector Body (Male) .............................................................................. 4
4 1476108 Wire Seal .................................................................................................... 4
5 ..... Connector Assembly (Low LPG Sensor) ........................................................ 1
5 1547629 Connector ................................................................................................... 1
5 1508232 Terminal ..................................................................................................... 3
5 1323579 Seal ............................................................................................................ 3
6 ..... Connector Assembly (Air Restriction Sensor Cap) ........................................ 1
6 1465468 Connector ................................................................................................... 1
6 1327164 Seal ............................................................................................................ 2
7 ..... Connector Assembly (Air Restriction Sensor) ................................................ 1
7 1465469 Connector ................................................................................................... 1
7 1323578 Terminal ..................................................................................................... 2
7 1402888 Seal ............................................................................................................ 2
8 ..... Connector Assembly (Relay) .......................................................................... 1
8 1461743 Relay .......................................................................................................... 1
9 ..... Connector Assembly (Latch Relay) ................................................................ 1
9 1461744 Connector Body ......................................................................................... 1
9 1503088 Lock ............................................................................................................ 1
9 1327164 Seal ............................................................................................................ 1
9 1402912 Terminal ..................................................................................................... 4
9 1323579 Seal ............................................................................................................ 4

©2011 HYSTER COMPANY See Service Manual 4-101

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-37)

LEFT HAND CHASSIS — GM 4.3L LPG (2010 SERIES)(WITHOUT PREMIUM LOW FUEL SENSOR)
(S/N G004V04608H → INC. 04572)

4-102 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
LEFT HAND CHASSIS – GM 4.3L LPG (2010 SERIES)(WITHOUT PREMIUM LOW FUEL SENSOR)
(S/N G004V04608H → INC. 04572)

ITEM PART NO. DESCRIPTION QTY

4604393 Wire Harness (LH Chassis) (Left Hand Chassis) ............................................... 1
1 ..... Connector Assembly (To Engine Harness) .................................................... 1
1 4006330 Connector ................................................................................................... 1
1 1527305 Connector Lock .......................................................................................... 1
1 1402927 Terminal ..................................................................................................... 9
1 1402929 Wire Seal .................................................................................................... 3
1 1507571 Seal ............................................................................................................ 9
2 1509888 Clip ................................................................................................................. 2
3 ..... Connector Assembly (Air Restriction Sensor) ................................................ 1
3 1465469 Connector ................................................................................................... 1
3 1323578 Terminal ..................................................................................................... 2
3 1402888 Seal ............................................................................................................ 20
4 ..... Connector Assembly (Air Restriction Sensor Cap) ........................................ 1
4 1465468 Connector ................................................................................................... 1
4 1327164 Seal ............................................................................................................ 2
5 ..... Connector Assembly (LPG Lockoff) ............................................................... 1
5 1599337 Connector ................................................................................................... 1
5 1623057 Terminal ..................................................................................................... 2
6 ..... Connector Asembly (Low LPG Switch) .......................................................... 1
6 1329152 Plug ............................................................................................................ 1
6 1329151 Terminal ..................................................................................................... 1
6 1329148 Terminal ..................................................................................................... 2
6 1402888 Seal ............................................................................................................ 2
7 ..... Connector Assembly (Rear Oxygen Sensor) ................................................. 1
7 1498424 Housing ...................................................................................................... 1
7 1650797 Lock ............................................................................................................ 1
7 1482666 Connector Body (Male) .............................................................................. 4
7 1476108 Wire Seal .................................................................................................... 4
8 ..... Connector Assembly (Relay) .......................................................................... 1
8 1461743 Relay .......................................................................................................... 1
9 ..... Connector Assembly (Latch Relay) ................................................................ 1
9 1461744 Connector Body ......................................................................................... 1
9 1503088 Lock ............................................................................................................ 1
9 1327164 Seal ............................................................................................................ 1
9 1402912 Terminal ..................................................................................................... 4
9 1323579 Seal ............................................................................................................ 4

©2011 HYSTER COMPANY See Service Manual 4-103

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-38)

ENGINE — GM 4.3L, GASOLINE (→ S/N G004V03165E)

4-104 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
ENGINE – GM 4.3L, GASOLINE (→ S/N G004V03165E)

ITEM PART NO. DESCRIPTION QTY

2087702 Wire Harness (Engine) ....................................................................................... 1
1 1540944 Clip ................................................................................................................. 4
2 1531502 Connector ....................................................................................................... 1
3 1327957 Connector (Oil Pressure) ................................................................................ 1
4 1482667 Connector Body (To Left Hand Chassis) ........................................................ 1
5 1500900 Clip ................................................................................................................. 1
6 1547483 Connector (To Ignition/MAP) .......................................................................... 2
7 148614 E-Ring (To Alternator) .................................................................................... 1
8 1566146 Boot ................................................................................................................ 1
9 148615 E-Ring (To Starter) ......................................................................................... 1
10 1519025 Ring Terminal (To Starter) .............................................................................. 1
11 1476064 Connector (Crank Position) ............................................................................ 1
12 1509888 Clip ................................................................................................................. 2
13 132972 Clamp ............................................................................................................. 1
14 1323586 Connector (To Alternator) ............................................................................... 1
15 ..... Fuse Holder Assembly ................................................................................... 1
15 1543553 Fuse Holder ................................................................................................ 1
15 1454829 Fuse (60 Amp) ........................................................................................... 1
15 1454862 Cover (With Seal) ....................................................................................... 1
15 1454827 Seal ............................................................................................................ 2
15 1520543 Terminal ..................................................................................................... 2
16 1476071 Connector (To Coil) ........................................................................................ 1
17 181089 Clamp ............................................................................................................. 1
18 1476067 Connector (Cam Position) .............................................................................. 1

©2011 HYSTER COMPANY See Service Manual 4-105

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-39)

ENGINE — GM 4.3L, GASOLINE (S/N G004V03166E ↔ S/N G004V04601H EXC. 04572)

4-106 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
ENGINE – GM 4.3L, GASOLINE (S/N G004V03166E ↔ S/N G004V04601H EXC. 04572)

ITEM PART NO. DESCRIPTION QTY

2093681 Wire Harness (Engine) (2008 - 2009 Series) ...................................................... 1
1 ..... Connector Assembly (Starter) ........................................................................ 1
1 1519025 Ring Terminal ............................................................................................. 1
2 ..... Connector Assembly (Crank Position) ........................................................... 1
2 1655119 Electrical Connector ................................................................................... 1
2 1655120 Electrical Terminal ...................................................................................... 3
2 1655121 Seal ............................................................................................................ 3
3 ..... Connector Assembly (Injector 3) .................................................................... 1
4 ..... Connector Assembly (Injector 5) .................................................................... 1
5 ..... Connector Assembly (Injector 1) .................................................................... 1
6 ..... Connector Assembly (Right Oxygen Sensor) ................................................. 1
6 1482667 Connector Body ......................................................................................... 1
6 1330355 Terminal ..................................................................................................... 4
6 1402877 Electrical Terminal ...................................................................................... 4
6 1482663 Connector ................................................................................................... 1
7 ..... Connector Assembly (Temperature Sensor) .................................................. 1
7 1323586 Connector ................................................................................................... 1
7 1354237 Terminal ..................................................................................................... 2
8 ..... Connector Assembly (Connector) .................................................................. 1
8 1607743 Connector ................................................................................................... 1
9 ..... Connector Assembly (Connector) .................................................................. 1
9 1543553 Fuse Holder ................................................................................................ 1
9 1454829 Fuse (60 Amp) ........................................................................................... 1
9 1454862 Cover (With Seal) ....................................................................................... 1
9 1454827 Seal ............................................................................................................ 2
9 1520543 Terminal ..................................................................................................... 2
10 ..... Connector Assembly (Alternator) ................................................................... 1
10 1323586 Connector ................................................................................................... 1
10 1323576 Terminal ..................................................................................................... 2
11 ..... Connector Assembly (Injector 2) .................................................................... 1
12 ..... Connector Assembly (Coil) ............................................................................. 1
12 1476071 Connector ................................................................................................... 1
12 1402877 Electrical Terminal ...................................................................................... 2
12 1330356 Seal ............................................................................................................ 3
12 1351139 Seal ............................................................................................................ 1
12 1476109 Connector Lock .......................................................................................... 1
13 ..... Connector Assembly (Injector 6) .................................................................... 1
14 ..... Connector Assembly (LH Chassis) ................................................................ 1
14 1527275 Connector ................................................................................................... 1
14 1402809 Clip ............................................................................................................. 1
15 ..... Connector Assembly (Cam Positioner Sensor) .............................................. 1
15 1476067 Connector ................................................................................................... 1
15 1476109 Connector Lock .......................................................................................... 1
15 1330355 Terminal ..................................................................................................... 3
15 1476108 Wire Seal .................................................................................................... 3
16 ..... Connector Assembly (CPS205) ..................................................................... 1
17 ..... Connector Assembly (CPS203) ..................................................................... 1
18 ..... Connector Assembly (CPS204) ..................................................................... 1
19 ..... Connector Assembly (Chassis Harness) ........................................................ 1
19 1541988 Connector ................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-107

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
ENGINE – GM 4.3L, GASOLINE (S/N G004V03166E ↔ S/N G004V04601H EXC. 04572)

ITEM PART NO. DESCRIPTION QTY

20 ..... Connector Assembly (Chassis Harness) ........................................................ 1
20 1330413 Connector ................................................................................................... 1
21 ..... Connector Assembly (Chassis Harness) ........................................................ 1
21 1514597 Connector ................................................................................................... 1
22 ..... Connector Assembly (Oil Pressure) ............................................................... 1
22 1327957 Connector ................................................................................................... 1
22 1354237 Terminal ..................................................................................................... 3
23 ..... Connector Assembly (Left Oxygen Sensor) ................................................... 1
23 1482667 Connector Body ......................................................................................... 1
23 1330355 Terminal ..................................................................................................... 4
23 1402877 Electrical Terminal ...................................................................................... 4
23 1482663 Connector ................................................................................................... 1
24 ..... Connector Assembly (Map Sensor) ............................................................... 1
24 1607839 Connector ................................................................................................... 1
24 1402814 Terminal ..................................................................................................... 4
24 1562649 Seal ............................................................................................................ 4
25 ..... Connector Assembly (Ignition) ....................................................................... 1
25 1547483 Connector ................................................................................................... 1
25 1354237 Terminal ..................................................................................................... 1
25 1476109 Connector Lock .......................................................................................... 1
25 1323576 Terminal ..................................................................................................... 3
26 ..... Connector Assembly (Injector 4) .................................................................... 1
27 ..... Connector Assembly (Alternator) ................................................................... 1
27 148614 E-Ring ........................................................................................................ 1
27 1566146 Boot ............................................................................................................ 1
28 ..... Connector Assembly (Battery) ....................................................................... 1
28 129886 E-Ring ........................................................................................................ 1

4-108 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-109

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (ENGINE) (FIGURE 4-40)

GM 4.3L GASOLINE (2010 SERIES) (S/N G004V04608H → INC. 04572)

4-110 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS (ENGINE)

GM 4.3L GASOLINE (2010 SERIES) (S/N G004V04608H → INC. 04572)

ITEM PART NO. DESCRIPTION QTY

4601159 Wire Harness (Engine) (2010 - 2011 Series) ................................................... 1
1 ..... Connector Assembly (Starter) .................................................................... 1
1 1519025 Ring Terminal ........................................................................................... 1
2 ..... Connector Assembly (Crank Position) ....................................................... 1
2 1655119 Electrical Connector ................................................................................ 1
2 1655120 Electrical Terminal ................................................................................... 3
2 1655121 Seal ............................................................................................................ 3
2 4001358 Retainer ..................................................................................................... 1
3 ..... Connector Assembly (Injector #3) .............................................................. 1
4 1509888 Clip ................................................................................................................. 2
5 ..... Connector Assembly (Injector #5) .............................................................. 1
6 132972 Clamp ............................................................................................................ 1
7 ..... Connector Assembly (Injector #1) .............................................................. 1
8 ..... Connector Assembly (Right Oxygen Sensor) ........................................... 1
8 1482667 Connector Body ....................................................................................... 1
8 1330355 Terminal .................................................................................................... 4
8 1402877 Electrical Terminal ................................................................................... 4
8 1482663 Connector ................................................................................................. 1
9 ..... Connector Assembly (Coolant Temperature Sensor) ............................... 1
9 1323586 Connector ................................................................................................. 1
9 1354237 Terminal .................................................................................................... 2
10 ..... Connector Assembly (Electronic Throttle Body) ...................................... 1
10 1607743 Connector ................................................................................................. 1
11 ..... Connector Assembly (Connector) .............................................................. 1
11 4008604 Fuse ........................................................................................................... 1
11 4007984 Connector (Fuse Holder) ............................................................................ 1
12 ..... Connector Assembly (Alternator, Positive) ............................................... 1
12 148614 E-Ring ........................................................................................................ 1
12 1566146 Boot ........................................................................................................... 1
13 ..... Connector Assembly (Alternator) ............................................................... 1
13 1323586 Connector ................................................................................................. 1
13 1323576 Terminal .................................................................................................... 1
14 ..... Connector Assembly (Injector #4) .............................................................. 1
15 ..... Connector Assembly (Coil) ......................................................................... 1
15 1476071 Connector ................................................................................................. 1
15 1402877 Electrical Terminal ................................................................................... 2
15 1330356 Seal ............................................................................................................ 3
15 1351139 Seal ............................................................................................................ 1
15 1476109 Connector Lock ........................................................................................ 1
16 181089 Clamp ............................................................................................................ 1
17 ..... Connector Assembly (Injector #6) .............................................................. 1
18 1500900 Clip ................................................................................................................. 2
19 ..... Connector Assembly (To Left Hand Chassis Harness) ............................ 1
19 4006329 Connector ................................................................................................. 1
19 1402809 Clip ............................................................................................................ 1
20 ..... Connector Assembly (Cam Position Sensor) ............................................ 1
20 1476067 Connector ................................................................................................. 1
20 1476109 Connector Lock ........................................................................................ 1
20 1330355 Terminal .................................................................................................... 3
20 1476108 Wire Seal ................................................................................................... 3

©2011 HYSTER COMPANY See Service Manual 4-111

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (ENGINE)

GM 4.3L GASOLINE (2010 SERIES) (S/N G004V04608H → INC. 04572)

ITEM PART NO. DESCRIPTION QTY

21 ..... Connector Assembly (CPS205) ................................................................... 1
22 ..... Connector Assembly (CPS203) ................................................................... 1
23 ..... Connector Assembly (CPS204) ................................................................... 1
24 1558227 Clip ................................................................................................................. 2
24 1532779 Clip ................................................................................................................. 2
25 1540944 Clip ................................................................................................................. 4
26 1540944 Clip ................................................................................................................. 1
27 ..... Connector Assembly (Chassis Harness) ................................................... 1
27 1541988 Connector ................................................................................................. 1
28 ..... Connector Assembly (Chassis Harness) ................................................... 1
28 1330413 Connector ................................................................................................. 1
29 ..... Connector Assembly (Chassis Harness) ................................................... 1
29 1514597 Connector ................................................................................................. 1
30 ..... Connector Assembly (Oil Pressure) ........................................................... 1
30 1327957 Connector ................................................................................................. 1
30 1354237 Terminal .................................................................................................... 3
31 ..... Connector Assembly (Left Oxygen Sensor) .............................................. 1
31 1482667 Connector Body ....................................................................................... 1
31 1330355 Terminal .................................................................................................... 4
31 1402877 Electrical Terminal ................................................................................... 4
31 1482663 Connector ................................................................................................. 1
32 ..... Connector Assembly (MAP/MAT Sensor) .................................................. 1
32 1607839 Connector ................................................................................................. 1
32 1402814 Terminal .................................................................................................... 4
32 1562649 Seal ............................................................................................................ 4
33 ..... Connector Assembly (Ignition) ................................................................... 1
33 1547483 Connector ................................................................................................. 1
33 1354237 Terminal .................................................................................................... 1
33 1476109 Connector Lock ........................................................................................ 1
33 1323576 Terminal .................................................................................................... 3
34 ..... Connector Assembly (Injector #4) .............................................................. 1
35 ..... Connector Assembly (Battery, Positive) .................................................... 1
35 129886 E-Ring ........................................................................................................ 1

4-112 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-113

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-41)

ENGINE — GM 4.3L, LPG (→ S/N G004V02853E)

4-114 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
ENGINE – GM 4.3L, LPG (→ S/N G004V02853E)

ITEM PART NO. DESCRIPTION QTY

2087701 Wire Harness (Engine) (To RH Chassis Harness) ............................................. 1
1 1531502 Connector ....................................................................................................... 5
2 1327957 Connector (Oil/Fuel Pressure) ........................................................................ 1
3 1500901 Clip (Cam Sensor) .......................................................................................... 1
4 ..... Connector Assembly (To LH Chassis Harness) ............................................. 1
4 1402809 Clip ............................................................................................................. 1
4 1527275 Connector ................................................................................................... 1
5 1482667 Connector Body (To Oxygen Sensor) ............................................................ 2
6 1476067 Connector (To Cam Sensor) .......................................................................... 1
7 1547483 Connector (To Ignition) ................................................................................... 2
8 1476071 Connector (To Coil) ........................................................................................ 1
9 1476064 Connector (Crank Position) ............................................................................ 1
10 1509888 Clip ................................................................................................................. 1
11 1607743 Connector ....................................................................................................... 1
12 1323586 Connector (To Coolant Temp Sensor) ........................................................... 1
13 ..... Fuse Holder Assembly (Starter Recharge Fuse) ........................................... 1
13 1543553 Fuse Holder ................................................................................................ 1
13 1454829 Fuse (60 Amp) ........................................................................................... 1
13 1454862 Cover (With Seal) ....................................................................................... 1
13 1454827 Seal ............................................................................................................ 2
13 1520543 Terminal ..................................................................................................... 2
14 ..... Connector Assembly (To Alternator) .............................................................. 1
14 148614 E-Ring ........................................................................................................ 1
14 1566146 Boot ............................................................................................................ 1
15 148615 E-Ring (To Battery Positive) ........................................................................... 1
16 1519025 Ring Terminal (To Starter) .............................................................................. 1
17 1607839 Connector (MAP/MAT) ................................................................................... 1
18 1532779 Clip ................................................................................................................. 1
19 1558226 Clip ................................................................................................................. 1
20 1540944 Clip ................................................................................................................. 5
21 ..... Connector ....................................................................................................... 5
22 ..... Connector ....................................................................................................... 6

©2011 HYSTER COMPANY See Service Manual 4-115

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-42)

ENGINE — GM 4.3L, LPG (S/N G004V02854E ↔ S/N G004V04601H EXC. 04572)

4-116 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
ENGINE – GM 4.3L, LPG (S/N G004V02854E ↔ S/N G004V04601H EXC. 04572)

ITEM PART NO. DESCRIPTION QTY

2093682 Wire Harness (Engine) (2008 - 2009 Series) ...................................................... 1
1 ..... Connector Assembly (Chassis Harness) ........................................................ 1
1 1541988 Connector ................................................................................................... 1
2 ..... Connector Assembly (Chassis Harness) ........................................................ 1
2 1330413 Connector ................................................................................................... 1
3 ..... Connector Assembly (Chassis Harness) ........................................................ 1
3 1514597 Connector ................................................................................................... 1
4 ..... Connector Assembly (Injector 5) .................................................................... 1
4 1561146 Terminal ..................................................................................................... 2
4 1607548 Connector ................................................................................................... 1
5 ..... Connector Assembly (Injector 3) .................................................................... 1
5 1561146 Terminal ..................................................................................................... 2
5 1607548 Connector ................................................................................................... 1
6 ..... Connector Assembly (Injector 1) .................................................................... 1
6 1561146 Terminal ..................................................................................................... 2
6 1607548 Connector ................................................................................................... 1
7 ..... Connector Assembly (CPS202) ..................................................................... 1
8 ..... Connector Assembly (CPS 249) .................................................................... 1
9 ..... Connector Assembly (CPS203) ..................................................................... 1
10 ..... Connector Assembly (CPS204) ..................................................................... 1
11 ..... Connector Assembly (CPS205) ..................................................................... 1
12 ..... Connector Assembly (RH Oxygen Sensor) .................................................... 1
12 1482667 Connector Body ......................................................................................... 1
12 1402877 Electrical Terminal ...................................................................................... 4
12 1330355 Terminal ..................................................................................................... 4
12 1482663 Connector ................................................................................................... 1
13 ..... Connector Assembly (Connector) .................................................................. 1
13 1323586 Connector ................................................................................................... 1
13 1354237 Terminal ..................................................................................................... 2
14 ..... Connector Assembly (Oil Pressure) ............................................................... 1
14 1327957 Connector ................................................................................................... 1
14 1354237 Terminal ..................................................................................................... 3
15 ..... Connector Assembly (Cam Sensor) ............................................................... 1
15 1476067 Connector ................................................................................................... 1
15 1476109 Connector Lock .......................................................................................... 1
15 1330355 Terminal ..................................................................................................... 3
15 1476108 Wire Seal .................................................................................................... 3
16 ..... Connector Assembly (Fuel Pressure) ............................................................ 1
16 1402613 Connector ................................................................................................... 1
16 1323576 Terminal ..................................................................................................... 3
17 ..... Connector Assembly (Injector 6) .................................................................... 1
17 1561146 Terminal ..................................................................................................... 2
17 1607548 Connector ................................................................................................... 1
18 ..... Connector Assembly (Injector 4) .................................................................... 1
18 1561146 Terminal ..................................................................................................... 2
18 1607548 Connector ................................................................................................... 1
19 ..... Connector Assembly (Injector 2) .................................................................... 1
19 1561146 Terminal ..................................................................................................... 2
19 1607548 Connector ................................................................................................... 1
20 ..... Connector Assembly (Battery) ....................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-117

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
ENGINE – GM 4.3L, LPG (S/N G004V02854E ↔ S/N G004V04601H EXC. 04572)

ITEM PART NO. DESCRIPTION QTY

20 129886 E-Ring ........................................................................................................ 1
21 ..... Connector Assembly (Starter) ........................................................................ 1
21 1519025 Ring Terminal ............................................................................................. 1
22 ..... Connector Assembly (Crank Position Sensor) ............................................... 1
22 1655119 Electrical Connector ................................................................................... 1
22 1655120 Electrical Terminal ...................................................................................... 3
22 1655121 Seal ............................................................................................................ 3
22 4001358 Retainer ...................................................................................................... 1
23 ..... Connector Assembly (Connector) .................................................................. 1
23 1607743 Connector ................................................................................................... 1
24 ..... Connector Assembly (Connector) .................................................................. 1
24 1543553 Fuse Holder ................................................................................................ 1
24 1454829 Fuse (60 Amp) ........................................................................................... 1
24 1520543 Terminal ..................................................................................................... 2
25 ..... Connector Assembly (Cover) ......................................................................... 1
25 1454862 Cover (With Seal) ....................................................................................... 1
26 ..... Connector Assembly (Connector) .................................................................. 1
26 1454827 Seal ............................................................................................................ 1
27 ..... Connector Assembly (Alternator) ................................................................... 1
27 1323576 Terminal ..................................................................................................... 2
27 1323586 Connector ................................................................................................... 1
28 ..... Connector Assembly (Alternator) ................................................................... 1
28 148614 E-Ring ........................................................................................................ 1
29 ..... Connector Assembly (LH Chassis Harness) .................................................. 1
29 1402809 Clip ............................................................................................................. 1
29 1527275 Connector ................................................................................................... 1
30 ..... Connector Assembly (Coil) ............................................................................. 1
30 1476071 Connector ................................................................................................... 1
30 1402877 Electrical Terminal ...................................................................................... 2
30 1476109 Connector Lock .......................................................................................... 1
30 1330356 Seal ............................................................................................................ 3
30 1351139 Seal ............................................................................................................ 1
31 ..... Connector Assembly (Ignition) ....................................................................... 1
31 1547483 Connector ................................................................................................... 1
31 1354237 Terminal ..................................................................................................... 1
31 1323576 Terminal ..................................................................................................... 3
31 1476109 Connector Lock .......................................................................................... 1
32 ..... Connector Assembly (Map Sensor) ............................................................... 1
32 1607839 Connector ................................................................................................... 1
32 1402814 Terminal ..................................................................................................... 4
32 1562649 Seal ............................................................................................................ 4
33 ..... Connector Assembly (LH Oxygen Sensor) .................................................... 1
33 1482663 Connector ................................................................................................... 1
33 1330355 Terminal ..................................................................................................... 4
33 1402877 Electrical Terminal ...................................................................................... 4
33 1482667 Connector Body ......................................................................................... 1

4-118 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-119

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (ENGINE) (FIGURE 4-43)

GM 4.3L LPG (2010 SERIES) (S/N G004V04608H → INC. 04572)

4-120 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS (ENGINE)

GM 4.3L LPG (2010 SERIES) (S/N G004V04608H → INC. 04572)

ITEM PART NO. DESCRIPTION QTY

4601160 Wire Harness (Engine) (2010 - 2011 Series) ...................................................... 1
1 ..... Connector Assembly (Chassis Harness) ........................................................ 1
1 1541988 Connector ................................................................................................... 1
2 ..... Connector Assembly (Chassis Harness) ........................................................ 1
2 1330413 Connector ................................................................................................... 1
3 ..... Connector Assembly (Chassis Harness) ........................................................ 1
3 1514597 Connector ................................................................................................... 1
4 ..... Connector Assembly (Injector #5) .................................................................. 1
4 1561146 Terminal ..................................................................................................... 2
4 1607548 Connector ................................................................................................... 1
5 ..... Connector Assembly (Injector #3) .................................................................. 1
5 1561146 Terminal ..................................................................................................... 2
5 1607548 Connector ................................................................................................... 1
6 ..... Connector Assembly (Injector #1) .................................................................. 1
6 1561146 Terminal ..................................................................................................... 2
6 1607548 Connector ................................................................................................... 1
7 1558227 Clip ................................................................................................................. 2
8 1532778 Clip ................................................................................................................. 2
9 1532779 Clip ................................................................................................................. 1
10 ..... Connector Assembly (CPS203) ..................................................................... 1
11 ..... Connector Assembly (CPS204) ..................................................................... 1
12 ..... Connector Assembly (CPS205) ..................................................................... 1
13 ..... Connector Assembly (Right Hand Oxygen Sensor) ....................................... 1
13 1482667 Connector Body ......................................................................................... 1
13 1402877 Electrical Terminal ...................................................................................... 4
13 1330355 Terminal ..................................................................................................... 4
13 1482663 Connector ................................................................................................... 1
14 ..... Connector Assembly (CTS) ............................................................................ 1
14 1323586 Connector ................................................................................................... 1
14 1354237 Terminal ..................................................................................................... 2
15 1509889 Clip ................................................................................................................. 1
16 ..... Connector Assembly (Oil Pressure) ............................................................... 1
16 1327957 Connector ................................................................................................... 1
16 1354237 Terminal ..................................................................................................... 3
17 ..... Connector Assembly (Cam Sensor) ............................................................... 1
17 1476067 Connector ................................................................................................... 1
17 1476109 Connector Lock .......................................................................................... 1
17 1330355 Terminal ..................................................................................................... 3
17 1476108 Wire Seal .................................................................................................... 3
18 1608857 Clip ................................................................................................................. 2
19 ..... Connector Assembly (Fuel ABS Pressure) .................................................... 1
19 1402613 Connector ................................................................................................... 1
19 1323576 Terminal ..................................................................................................... 3
20 ..... Connector Assembly (Injector #6) .................................................................. 1
20 1607548 Connector ................................................................................................... 1
20 1561146 Terminal ..................................................................................................... 2
21 ..... Connector Assembly (Injector #4) .................................................................. 1
21 1607548 Connector ................................................................................................... 1
21 1561146 Terminal ..................................................................................................... 2
22 ..... Connector Assembly (Injector #2) .................................................................. 1

©2011 HYSTER COMPANY See Service Manual 4-121

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (ENGINE)

GM 4.3L LPG (2010 SERIES) (S/N G004V04608H → INC. 04572)

ITEM PART NO. DESCRIPTION QTY

22 1607548 Connector ................................................................................................... 1
22 1561146 Terminal ..................................................................................................... 2
23 ..... Connector Assembly (Battery, Positive) ......................................................... 1
23 129886 E-Ring ........................................................................................................ 1
24 ..... Connector Assembly (Starter) ........................................................................ 1
24 1519025 Ring Terminal ............................................................................................. 1
25 ..... Connector Assembly (Crank Position) ........................................................... 1
25 1655119 Electrical Connector ................................................................................... 1
25 1655120 Electrical Terminal ...................................................................................... 3
25 1655121 Seal ............................................................................................................ 3
25 4001358 Retainer ...................................................................................................... 1
26 1500901 Clip ................................................................................................................. 1
27 ..... Connector Assembly (Electronic Throttle Body) ............................................. 1
27 1607743 Connector ................................................................................................... 1
28 148614 E-Ring ............................................................................................................ 1
28 1566146 Boot ................................................................................................................ 1
29 ..... Connector Assembly) (Fuse Holder) .............................................................. 1
29 4008604 Fuse ........................................................................................................... 1
29 4007984 Connector (Fuse Holder) ............................................................................ 1
30 ..... Connector Assembly (Alternator) ................................................................... 1
30 1323576 Terminal ..................................................................................................... 2
30 1323586 Connector ................................................................................................... 1
31 ..... Connector Assembly (Left Hand Oxygen Sensor) ......................................... 1
31 1402809 Clip ............................................................................................................. 1
31 4006329 Connector ................................................................................................... 1
32 ..... Connector Assembly (Coil) ............................................................................. 1
32 1476071 Connector ................................................................................................... 1
32 1402877 Electrical Terminal ...................................................................................... 2
32 1476109 Connector Lock .......................................................................................... 1
32 1330356 Seal ............................................................................................................ 3
32 1351139 Seal ............................................................................................................ 1
33 1500900 Clip ................................................................................................................. 3
34 ..... Connector Assembly (MAP/MAT) .................................................................. 1
34 1607839 Connector ................................................................................................... 1
34 1402814 Terminal ..................................................................................................... 4
34 1562649 Seal ............................................................................................................ 4
35 ..... Connector Assembly (Ignition) ....................................................................... 1
35 1547483 Connector ................................................................................................... 1
35 1354237 Terminal ..................................................................................................... 1
35 1323576 Terminal ..................................................................................................... 3
35 1476109 Connector Lock .......................................................................................... 1
36 ..... Connector Assembly (Left Hand Oxygen Sensor) ......................................... 1
36 1482663 Connector ................................................................................................... 1
36 1330355 Terminal ..................................................................................................... 4
36 1402877 Electrical Terminal ...................................................................................... 4
36 1482667 Connector Body ......................................................................................... 1
37 1570327 Bracket ........................................................................................................... 1
38 1532778 Clip ................................................................................................................. 2

4-122 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS (FIGURE 4-44)

SEALED ALTERNATOR — GM 4.3L

ITEM PART NO. DESCRIPTION QTY

2094582 Wire Harness Sealed Alternator ......................................................................... 1
1 ..... Connector Assembly (To Disconnect Switch Link) ......................................... 2
1 181045 Connector Body ......................................................................................... 1
1 134810 Terminal ..................................................................................................... 1
2 1469606 Adapter (To Engine Harness) ......................................................................... 1
3 ..... Connector Assembly (To Engine Harness) .................................................... 1
3 1323586 Connector ................................................................................................... 1
3 1323576 Terminal ..................................................................................................... 2
4 ..... Connector Assembly (To Disconnect Switch Link) ......................................... 2
4 181046 Connector Body ......................................................................................... 1
4 1561117 Terminal ..................................................................................................... 1
5 1402816 Clip ................................................................................................................. 1
6 ..... Connector Assembly (To Disconnect Switch) ................................................ 2
6 1582218 E-Ring ........................................................................................................ 1
6 190383 Boot ............................................................................................................ 1
6 175944 Heat Shrink ................................................................................................ 1
7 ..... Connector Assembly (Alternator Excite) ........................................................ 1
7 181046 Connector Body ......................................................................................... 1
7 1561117 Terminal ..................................................................................................... 1
8 ..... Connector Assembly (Alternator D+) .............................................................. 1
8 1582218 E-Ring ........................................................................................................ 1
8 190383 Boot ............................................................................................................ 1
8 175944 Heat Shrink ................................................................................................ 1
9 ..... Connector Assembly (Alternator Field) .......................................................... 1
9 181045 Connector Body ......................................................................................... 1
9 134810 Terminal ..................................................................................................... 1
10 ..... Connector Assembly (Diode Pack) ................................................................ 1

©2011 HYSTER COMPANY See Service Manual 4-123

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ITEM PART NO. DESCRIPTION QTY

10 1489656 Connector (4-Way) ..................................................................................... 1
10 1489657 Connector ................................................................................................... 1
10 1363886 Terminal (Socket) ....................................................................................... 4
11 2094490 Kit-Diode ......................................................................................................... 1

4-124 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-125

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-45)

COWL WITH FORWARD/REVERSE LEVER — MANUAL, WITH OPERATOR PRESENCE

4-126 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – MANUAL, WITH OPERATOR PRESENCE

ITEM PART NO. DESCRIPTION QTY

2104702 Wire Harness ...................................................................................................... 1
1 ..... Connector Assembly (To RH Chassis Harness) ............................................ 1
1 1489656 Connector (4-Way) ..................................................................................... 1
1 1489657 Connector ................................................................................................... 1
1 1330438 Terminal (Socket) ....................................................................................... 4
2 ..... Connector Assembly (VSM) ........................................................................... 1
2 1525568 Connector ................................................................................................... 1
2 1529046 Connector ................................................................................................... 1
2 1463139 Terminal ..................................................................................................... 8
2 1484377 Plug ............................................................................................................ 4
3 1540388 Conduit ........................................................................................................... 1
4 1534282 Clip ................................................................................................................. 1
5 ..... Connector Assembly (Hydraulic Lockout Solenoid) ....................................... 2
5 1484557 Connector ................................................................................................... 1
5 1484558 Connector ................................................................................................... 1
5 1463139 Terminal ..................................................................................................... 2
6 275493 Conduit ........................................................................................................... AR
7 ..... Connector Assembly (Accelerator Pedal Sensor) .......................................... 1
7 1525584 Connector ................................................................................................... 1
7 1532571 Terminal ..................................................................................................... 6
8 1509888 Clip ................................................................................................................. 4
9 ..... Connector Assembly (Brake Pressure) .......................................................... 1
9 1603021 Connector ................................................................................................... 1
9 1603236 Connector (Secondary Lock) ..................................................................... 1
9 1548517 Terminal (Socket) ....................................................................................... 3
9 1548519 Seal ............................................................................................................ 3
10 ..... Connector Assembly (Brake Fluid) ................................................................. 2
10 1324310 Terminal ..................................................................................................... 1
10 1324309 Sleeve ........................................................................................................ 1
11 275496 Conduit ........................................................................................................... AR
12 1534828 Clip ................................................................................................................. 1
13 ..... Connector Assembly (Park Brake) ................................................................. 1
13 1484397 Connector (3-Way) ..................................................................................... 1
13 1463194 Connector ................................................................................................... 1
13 1330438 Terminal (Socket) ....................................................................................... 3
14 ..... Connector Assembly (Brake Pedal) ............................................................... 1
14 1484397 Connector (3-Way) ..................................................................................... 1
14 1463194 Connector ................................................................................................... 1
14 1330438 Terminal (Socket) ....................................................................................... 3
15 1402816 Clip ................................................................................................................. 1
16 1500899 Clip ................................................................................................................. 1
17 275497 Conduit ........................................................................................................... AR
18 1525577 Connector (With Resistor) .............................................................................. 1
19 ..... Connector Assembly (Bus Terminal) .............................................................. 1
19 1489656 Connector (4-Way) ..................................................................................... 1
19 1489657 Connector ................................................................................................... 1
19 1330438 Terminal (Socket) ....................................................................................... 1
20 ..... Connector Assembly (Display) ....................................................................... 1
20 1525567 Connector ................................................................................................... 1
20 1529046 Connector ................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-127

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – MANUAL, WITH OPERATOR PRESENCE

ITEM PART NO. DESCRIPTION QTY

20 1463139 Terminal ..................................................................................................... 5
20 1484377 Plug ............................................................................................................ 7
21 ..... Connector Assembly (Diagnostic) .................................................................. 1
21 1566116 Connector ................................................................................................... 1
21 1532664 Connector (Secondary Lock) ..................................................................... 1
21 1330438 Terminal (Socket) ....................................................................................... 3
22 1566117 Dust Cap ........................................................................................................ 1
23 ..... Connector Assembly (Horn Button) ................................................................ 1
23 1490242 Connector ................................................................................................... 1
23 1490243 Connector ................................................................................................... 1
23 1330438 Terminal (Socket) ....................................................................................... 2
24 ..... Connector Assembly (VSM) ........................................................................... 1
24 1525570 Connector ................................................................................................... 1
24 1529046 Connector ................................................................................................... 1
24 1463139 Terminal ..................................................................................................... 7
24 1484377 Plug ............................................................................................................ 5
25 ..... Connector Assembly (To RH Chassis) ........................................................... 1
25 1500925 Connector ................................................................................................... 1
25 1352603 Connector ................................................................................................... 1
25 1330437 Terminal (Pin) ............................................................................................. 7
25 1484377 Plug ............................................................................................................ 5

4-128 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-129

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-46)

COWL WITH FORWARD/REVERSE LEVER — WITHOUT RETURN TO SET TILT

4-130 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – WITHOUT RETURN TO SET TILT

ITEM PART NO. DESCRIPTION QTY

2084829 Wire Harness (Cowl with Forward/Reverse Lever) ............................................. 1
2098012 Wire Harness (Cowl with Forward/Reverse Lever) (Alternate Part) ................... 1
1 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
1 1525568 Connector ................................................................................................... 1
1 1463139 Terminal ..................................................................................................... 7
1 1484377 Plug ............................................................................................................ 5
1 1529046 Connector ................................................................................................... 1
2 ..... Connector Assembly (Accelerator Pedal Sensor) .......................................... 1
2 1525584 Connector ................................................................................................... 1
2 1532571 Terminal ..................................................................................................... 6
3 1509888 Clip ................................................................................................................. 4
4 ..... Connector Assembly (Brake Pressure) .......................................................... 1
4 1603021 Connector ................................................................................................... 1
4 1603236 Connector (Secondary Lock) ..................................................................... 1
4 1548517 Terminal (Socket) ....................................................................................... 3
4 1548519 Seal ............................................................................................................ 3
5 1534828 Clip ................................................................................................................. 1
6 1402816 Clip ................................................................................................................. 1
7 ..... Connector Assembly (Park Brake) ................................................................. 2
7 1484397 Connector (3-Way) ..................................................................................... 1
7 1463194 Connector ................................................................................................... 1
7 1330438 Terminal (Socket) ........................................................................................... 3
8 ..... Connector Assembly (Brake Fluid) ................................................................. 2
8 1324309 Sleeve ........................................................................................................ 1
8 1324310 Terminal ..................................................................................................... 1
9 1525577 Connector (With Resistor) (End Cap) ............................................................. 1
10 ..... Connector Assembly ...................................................................................... 1
10 1489656 Connector (4-Way) ..................................................................................... 1
10 1489657 Connector ................................................................................................... 1
10 1330438 Terminal (Socket) ....................................................................................... 4
11 1500899 Clip ................................................................................................................. 2
12 ..... Connector Assembly (Display) ....................................................................... 1
12 1525567 Connector ................................................................................................... 1
12 1529046 Connector ................................................................................................... 1
12 1463139 Terminal ..................................................................................................... 5
12 1484377 Plug ............................................................................................................ 7
13 ..... Connector Assembly (J1939 Diagnostic) ....................................................... 1
13 1566116 Connector ................................................................................................... 1
13 1532664 Connector (Secondary Lock) ..................................................................... 1
13 1330438 Terminal (Socket) ....................................................................................... 3
13 1566117 Dust Cap .................................................................................................... 1
14 ..... Connector Assembly (Horn Button) ................................................................ 1
14 1490242 Connector ................................................................................................... 1
14 1490243 Connector ................................................................................................... 1
14 1330438 Terminal (Socket) ....................................................................................... 2
15 1534282 Clip ................................................................................................................. 1
16 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
16 1525570 Connector ................................................................................................... 1
16 1529046 Connector ................................................................................................... 1
16 1463139 Terminal ..................................................................................................... 7

©2011 HYSTER COMPANY See Service Manual 4-131

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
COWL WITH FORWARD/REVERSE LEVER – WITHOUT RETURN TO SET TILT

ITEM PART NO. DESCRIPTION QTY

16 1484377 Plug ............................................................................................................ 5
17 ..... Connector Assembly (To RH Chassis) ........................................................... 1
17 1500925 Connector ................................................................................................... 1
17 1352603 Connector ................................................................................................... 1
17 1330437 Terminal (Pin) ............................................................................................. 7
17 1484377 Plug ............................................................................................................ 5
18 ..... Connector Assembly (To RH Chassis) ........................................................... 1
18 1489656 Connector (4-Way) ..................................................................................... 1
18 1489657 Connector ................................................................................................... 1
18 1330438 Terminal (Socket) ....................................................................................... 4

4-132 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-133

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-47)

COWL WITH MONOTROL PEDAL — WITH RETURN TO SET TILT

4-134 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
COWL WITH MONOTROL PEDAL – WITH RETURN TO SET TILT

ITEM PART NO. DESCRIPTION QTY

2070269 Wire Harness ...................................................................................................... 1
2098011 Wire Harness (Alternate Part) ............................................................................. 1
1 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
1 1525568 Connector ................................................................................................... 1
1 1529046 Connector ................................................................................................... 1
1 1463139 Terminal ..................................................................................................... 11
1 1484377 Plug ............................................................................................................ 1
2 1525573 Connector ....................................................................................................... 1
3 ..... Connector Assembly (Monotrol) ..................................................................... 1
3 1489656 Connector (4-Way) ..................................................................................... 1
3 1489657 Connector ................................................................................................... 1
3 1330438 Terminal (Socket) ....................................................................................... 4
4 ..... Connector Assembly (Accelerator Pedal) ...................................................... 1
4 1525584 Connector ................................................................................................... 1
4 1532571 Terminal ..................................................................................................... 6
5 1509890 Clip ................................................................................................................. 4
6 ..... Connector Assembly (To Mast) ...................................................................... 1
6 1484397 Connector (3-Way) ..................................................................................... 1
6 1463194 Connector ................................................................................................... 1
6 1330438 Terminal (Socket) ....................................................................................... 3
7 1351682 Connector (End Cap) ..................................................................................... 1
8 ..... Connector Assembly (Brake Pressure) .......................................................... 1
8 1603021 Connector ................................................................................................... 1
8 1603236 Connector (Secondary Lock) ..................................................................... 1
8 1548517 Terminal (Socket) ....................................................................................... 3
8 1548519 Seal ............................................................................................................ 3
9 1534828 Clip ................................................................................................................. 1
10 1402816 Clip ................................................................................................................. 1
11 ..... Connector Assembly (Brake Pedal) ............................................................... 1
11 1463194 Connector ................................................................................................... 1
11 1484397 Connector (3-Way) ..................................................................................... 1
11 1330438 Terminal (Socket) ....................................................................................... 3
12 ..... Connector Assembly (Park Brake) ................................................................. 1
12 1463194 Connector ................................................................................................... 1
12 1484397 Connector (3-Way) ..................................................................................... 1
12 1330438 Terminal (Socket) ....................................................................................... 3
13 ..... Connector Assembly (Brake Fluid Sensor) .................................................... 2
13 1324309 Sleeve ........................................................................................................ 1
13 1324310 Terminal ..................................................................................................... 1
14 1525577 Connector (With Resistor) (End Cap) ............................................................. 1
15 ..... Connector Assembly (Bus Terminal 1) ........................................................... 1
15 1489656 Connector (4-Way) ..................................................................................... 1
15 1489657 Connector ................................................................................................... 1
15 1330438 Terminal (Socket) ....................................................................................... 4
16 1500899 Clip ................................................................................................................. 2
17 ..... Connector Assembly (Display) ....................................................................... 1
17 1525567 Connector ................................................................................................... 1
17 1529046 Connector ................................................................................................... 1
17 1463139 Terminal ..................................................................................................... 5
17 1484377 Plug ............................................................................................................ 7

©2011 HYSTER COMPANY See Service Manual 4-135

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
COWL WITH MONOTROL PEDAL – WITH RETURN TO SET TILT

ITEM PART NO. DESCRIPTION QTY

18 ..... Connector Assembly (J1939 Diagnostic) ....................................................... 1
18 1566116 Connector ................................................................................................... 1
18 1532664 Connector (Secondary Lock) ..................................................................... 1
18 1330438 Terminal (Socket) ....................................................................................... 3
19 ..... Connector Assembly (To Horn) ...................................................................... 1
19 1490242 Connector ................................................................................................... 1
19 1490243 Connector ................................................................................................... 1
19 1330438 Terminal (Socket) ....................................................................................... 2
20 1566117 Dust Cap ........................................................................................................ 1
21 1534282 Clip ................................................................................................................. 1
22 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
22 1525570 Connector ................................................................................................... 1
22 1529046 Connector ................................................................................................... 1
22 1463139 Terminal ..................................................................................................... 7
22 1484377 Plug ............................................................................................................ 5
23 ..... Connector Assembly (RH Chassis) ................................................................ 1
23 1500925 Connector ................................................................................................... 1
23 1352603 Connector ................................................................................................... 1
23 1330437 Terminal (Pin) ............................................................................................. 10
23 1484377 Plug ............................................................................................................ 2
24 ..... Connector Assembly (RH Chassis) ................................................................ 1
24 1489656 Connector (4-Way) ..................................................................................... 1
24 1330438 Terminal (Socket) ....................................................................................... 4
24 1489657 Connector ................................................................................................... 1

4-136 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-137

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-48)

COWL WITH MONOTROL PEDAL — WITH HYDRAULIC PUMP SOLENOID

4-138 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
COWL WITH MONOTROL PEDAL – WITH HYDRAULIC PUMP SOLENOID

ITEM PART NO. DESCRIPTION QTY

2104701 Wire Harness ..................................................................................................... 1
1 ..... Connector Assembly (Vehicle System Manager) ...................................... 1
1 1525568 Connector ................................................................................................. 1
1 1529046 Connector ................................................................................................. 1
1 1463139 Terminal .................................................................................................... 12
2 1540388 Conduit .......................................................................................................... AR
3 1534282 Clip ................................................................................................................. 1
4 ..... Connector Assembly (Hydraulic Lockout Solenoid 2) ............................. 1
4 1484557 Connector ................................................................................................. 1
4 1484558 Connector ................................................................................................. 1
4 1463139 Terminal .................................................................................................... 2
5 275493 Conduit .......................................................................................................... AR
6 ..... Connector Assembly ................................................................................... 1
6 1484557 Connector ................................................................................................. 1
6 1484558 Connector ................................................................................................. 1
6 1463139 Terminal .................................................................................................... 2
7 ..... Connector Assembly ................................................................................... 1
7 1525584 Connector ................................................................................................. 1
7 1532571 Terminal .................................................................................................... 6
8 1509888 Clip ................................................................................................................. 4
9 ..... Connector Assembly (To Monotrol Harness) ............................................ 1
9 1489656 Connector (4-Way) ................................................................................... 1
9 1489657 Connector ................................................................................................. 1
9 1330438 Terminal (Socket) ..................................................................................... 4
10 275496 Conduit .......................................................................................................... AR
11 1534828 Clip ................................................................................................................. 1
12 ..... Connector Assembly (Endcap) ................................................................... 1
12 1525573 Connector ................................................................................................. 1
13 ..... Connector Assembly (Brake Fluid) ............................................................ 1
13 1324310 Terminal .................................................................................................... 1
13 1324309 Sleeve ........................................................................................................ 1
14 ..... Connector Assembly (Brake Fluid) ............................................................ 1
14 1324310 Terminal .................................................................................................... 1
14 1324309 Sleeve ........................................................................................................ 1
15 ..... Connector Assembly (Park Brake) ............................................................. 1
15 1484397 Connector (3-Way) ................................................................................... 1
15 1463194 Connector ................................................................................................. 1
15 1330438 Terminal (Socket) ..................................................................................... 3
16 1402816 Clip ................................................................................................................. 1
17 275493 Conduit .......................................................................................................... AR
18 ..... Connector Assembly (Brake Pressure) ...................................................... 1
18 1603021 Connector ................................................................................................. 1
18 1603236 Connector (Secondary Lock) .................................................................. 1
18 1548517 Terminal (Socket) ..................................................................................... 3
18 1548519 Seal ............................................................................................................ 3
19 ..... Connector Assembly (Brake Pressure) ...................................................... 1
19 1484397 Connector (3-Way) ................................................................................... 1
19 1463194 Connector ................................................................................................. 1
19 1330438 Terminal (Socket) ..................................................................................... 3
20 1500899 Clip ................................................................................................................. 2

©2011 HYSTER COMPANY See Service Manual 4-139

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS
COWL WITH MONOTROL PEDAL – WITH HYDRAULIC PUMP SOLENOID

ITEM PART NO. DESCRIPTION QTY

21 275497 Conduit .......................................................................................................... AR
22 ..... Connector Assembly (Endcap with Resistor) ........................................... 1
22 1525577 Connector (With Resistor) ....................................................................... 1
23 ..... Connector Assembly (Bus Terminal 1) ...................................................... 1
23 1489656 Connector (4-Way) ................................................................................... 1
23 1489657 Connector ................................................................................................. 1
23 1330438 Terminal (Socket) ..................................................................................... 4
24 ..... Connector Assembly (Display) ................................................................... 1
24 1525567 Connector ................................................................................................. 1
24 1529046 Connector ................................................................................................. 1
24 1463139 Terminal .................................................................................................... 5
24 1484377 Plug ........................................................................................................... 7
25 ..... Connector Assembly (J1939 Diagnostic) ................................................... 1
25 1566116 Connector ................................................................................................. 1
25 1532664 Connector (Secondary Lock) .................................................................. 1
25 1330438 Terminal (Socket) ..................................................................................... 3
26 1566117 Dust Cap ........................................................................................................ 1
27 ..... Connector Assembly (Horn Button) ........................................................... 1
27 1490242 Connector ................................................................................................. 1
27 1490243 Connector ................................................................................................. 1
27 1330438 Terminal (Socket) ..................................................................................... 2
28 ..... Connector Assembly (Vehicle System Manager) ...................................... 1
28 1525570 Connector ................................................................................................. 1
28 1529046 Connector ................................................................................................. 1
28 1463139 Terminal .................................................................................................... 7
28 1484377 Plug ........................................................................................................... 5
29 ..... Connector Assembly (To RH Chassis Harness) ....................................... 1
29 1500925 Connector ................................................................................................. 1
29 1352603 Connector ................................................................................................. 1
29 1330437 Terminal (Pin) ........................................................................................... 7
29 1484377 Plug ........................................................................................................... 5
30 ..... Connector Assembly (To RH Chassis Harness) ....................................... 1
30 1489656 Connector (4-Way) ................................................................................... 1
30 1489657 Connector ................................................................................................. 1
30 1330438 Terminal (Socket) ..................................................................................... 4

4-140 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-141

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-49)

ELECTRONIC CONTROL VALVE — THREE FUNCTION

4-142 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
ELECTRONIC CONTROL VALVE – THREE FUNCTION

ITEM PART NO. DESCRIPTION QTY

2060198 Wire Harness (Electronic Control Valve) ............................................................ 1
1 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
1 1525564 Connector ................................................................................................... 1
1 1330438 Terminal (Socket) ....................................................................................... 9
1 1330439 Plug ............................................................................................................ 3
1 1525564 Connector ................................................................................................... 1
1 1500913 Connector ................................................................................................... 1
2 1402815 Clip ................................................................................................................. 4
3 ..... Connector Assembly (2A Tilt) ......................................................................... 1
3 1531162 Connector ................................................................................................... 1
3 1562649 Seal ............................................................................................................ 2
3 1402814 Terminal ..................................................................................................... 2
4 190383 Boot ................................................................................................................ 4
5 ..... Connector Assembly (2B Tilt) ......................................................................... 1
5 1531162 Connector ................................................................................................... 1
5 1562649 Seal ............................................................................................................ 2
5 1402814 Terminal ..................................................................................................... 2
6 ..... Connector Assembly (3B Auxiliary 1) ............................................................. 1
6 1493435 Connector (2-Way) ..................................................................................... 1
6 1562649 Seal ............................................................................................................ 2
6 1402814 Terminal ..................................................................................................... 2
7 ..... Connector Assembly (3A Auxiliary 1) ............................................................. 1
7 1493435 Connector (2-Way) ..................................................................................... 1
7 1562649 Seal ............................................................................................................ 2
7 1402814 Terminal ..................................................................................................... 2
8 ..... Connector Assembly (Lift) .............................................................................. 1
8 1490242 Connector ................................................................................................... 1
8 1330438 Terminal (Socket) ....................................................................................... 2
8 1490243 Connector ................................................................................................... 1
9 ..... Connector Assembly (Lower) ......................................................................... 1
9 1490242 Connector ................................................................................................... 1
9 1330438 Terminal (Socket) ....................................................................................... 2
9 1490243 Connector ................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-143

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-50)

ELECTRONIC CONTROL VALVE — FOUR FUNCTION

4-144 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
ELECTRONIC CONTROL VALVE – FOUR FUNCTION

ITEM PART NO. DESCRIPTION QTY

2058909 Wire Harness (Electronic Control Valve) ............................................................ 1
1 ..... Connector Assembly (Vehicle System Manager) ........................................... 1
1 1525564 Connector ................................................................................................... 1
1 1330438 Terminal (Socket) ....................................................................................... 12
1 1500913 Connector ................................................................................................... 1
2 1402815 Clip ................................................................................................................. 4
3 ..... Connector Assembly (2A Tilt) ......................................................................... 1
3 1531162 Connector ................................................................................................... 1
3 1562649 Seal ............................................................................................................ 2
3 1402814 Terminal ..................................................................................................... 2
4 190383 Boot ................................................................................................................ 6
5 ..... Socket Assembly (4A Aux2) ........................................................................... 1
5 1493447 Connector ................................................................................................... 1
5 1562649 Seal ............................................................................................................ 2
5 1402814 Terminal ..................................................................................................... 2
6 ..... Socket Assembly (4B Aux2) ........................................................................... 1
6 1493447 Connector ................................................................................................... 1
6 1562649 Seal ............................................................................................................ 2
6 1402814 Terminal ..................................................................................................... 2
7 ..... Connector Assembly (2B Tilt) ......................................................................... 1
7 1493435 Connector (2-Way) ..................................................................................... 1
7 1562649 Seal ............................................................................................................ 2
7 1402814 Terminal ..................................................................................................... 2
8 ..... Socket Assembly (3B Aux1) ........................................................................... 1
8 1493447 Connector ................................................................................................... 1
8 1562649 Seal ............................................................................................................ 2
8 1402814 Terminal ..................................................................................................... 2
9 ..... Connector Assembly (3A Aux1) ..................................................................... 1
9 1493435 Connector (2-Way) ..................................................................................... 1
9 1562649 Seal ............................................................................................................ 2
9 1402814 Terminal ..................................................................................................... 2
10 ..... Connector Assembly (Lift) .............................................................................. 1
10 1490242 Connector ................................................................................................... 1
10 1330438 Terminal (Socket) ....................................................................................... 2
10 1490243 Connector ................................................................................................... 1
11 ..... Connector Assembly (Lower) ......................................................................... 1
11 1490242 Connector ................................................................................................... 1
11 1330438 Terminal (Socket) ....................................................................................... 2
11 1490243 Connector ................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-145

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-51)

ELECTRONIC CONTROL VALVE — FIVE FUNCTION

4-146 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
ELECTRONIC CONTROL VALVE – FIVE FUNCTION

ITEM PART NO. DESCRIPTION QTY

2079402 Wire Harness (Electronic Control Valve) ............................................................ 1
1 ..... Connector Assembly (Auxiliary and Tilt) ........................................................ 8
1 1493447 Connector ................................................................................................... 1
1 1402814 Terminal ..................................................................................................... 2
1 1562649 Seal ............................................................................................................ 2
1 190383 Boot ............................................................................................................ 1
2 ..... Connector Assembly (To Hoist Pressure Sensor) .......................................... 1
2 1603021 Connector ................................................................................................... 1
2 1603236 Connector (Secondary Lock) ..................................................................... 1
2 1548517 Terminal (Socket) ....................................................................................... 3
2 190383 Boot ............................................................................................................ 2
3 ..... Connector Assembly (Lift) .............................................................................. 2
3 1490242 Connector ................................................................................................... 1
3 1490243 Connector ................................................................................................... 1
3 1330438 Terminal (Socket) ....................................................................................... 2
4 ..... Connector Assembly (To Vehicle System Manager) ...................................... 1
4 1525565 Connector ................................................................................................... 1
4 1500913 Connector ................................................................................................... 1
4 1330438 Terminal (Socket) ....................................................................................... 6
4 1484377 Plug ............................................................................................................ 6
5 ..... Connector Assembly (To Vehicle System Manager) ...................................... 1
5 1525564 Connector ................................................................................................... 1
5 1500913 Connector ................................................................................................... 1
5 1330438 Terminal (Socket) ....................................................................................... 12
6 1534828 Clip ................................................................................................................. 4

©2011 HYSTER COMPANY See Service Manual 4-147

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-52)

JOYSTICK

ITEM PART NO. DESCRIPTION QTY

2084703 Wire Harness (Joystick) ...................................................................................... 1
1 ..... Connector Assembly (To Joystick) ................................................................. 1
1 1616384 Connector ................................................................................................... 2
1 1616386 Terminal (Socket) ....................................................................................... 6
1 1616388 Collar (Joystick) .......................................................................................... 1
1 1616390 O-Ring ........................................................................................................ 1
2 1569995 Bushing .......................................................................................................... 1
3 ..... Connector Assembly (To Seat Harness) ........................................................ 1
3 1530960 Connector ................................................................................................... 1
3 1530961 Connector (Secondary Lock) ..................................................................... 1
3 1463140 Terminal (Pin) ............................................................................................. 6

4-148 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 4-149

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-53)

TRANSMISSION — SINGLE SPEED

4-150 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
TRANSMISSION – SINGLE SPEED

ITEM PART NO. DESCRIPTION QTY

2085943 Wire Harness (Transmission) ............................................................................. 1
1 ..... Connector Assembly (To RH Chassis Harness) ............................................ 1
1 1623280 Connector ................................................................................................... 1
1 1623281 Connector ................................................................................................... 1
1 1463138 Terminal ..................................................................................................... 10
1 1484377 Plug ............................................................................................................ 2
2 1402816 Clip ................................................................................................................. 1
3 1509888 Clip ................................................................................................................. 2
4 ..... Connector Assembly (Temperature) .............................................................. 1
4 1402868 Connector ................................................................................................... 1
4 1323576 Terminal ..................................................................................................... 2
5 ..... Connector Assembly (Clutch Forward/Reverse 1) ......................................... 1
5 1490242 Connector ................................................................................................... 1
5 1490243 Connector ................................................................................................... 1
5 1330438 Terminal (Socket) ....................................................................................... 2
6 ..... Connector Assembly (Forward/Reverse 1 Pressure) ..................................... 1
6 1603021 Connector ................................................................................................... 1
6 1603236 Connector (Secondary Lock) ..................................................................... 1
6 1548517 Terminal (Socket) ....................................................................................... 3
6 1548519 Seal ............................................................................................................ 3
7 ..... Connector Assembly (Turbine Shaft RPM) .................................................... 1
7 1546673 Connector ................................................................................................... 1
7 1323576 Terminal ..................................................................................................... 3
8 ..... Connector Assembly (Tail Shaft RPM) ........................................................... 1
8 1558156 Connector ................................................................................................... 1
8 1323576 Terminal ..................................................................................................... 4
9 1509890 Clip ................................................................................................................. 1
10 1402813 Clip ................................................................................................................. 1
11 ..... Connector Assembly (To RH Chassis Harness) ............................................ 1
11 1530960 Connector ................................................................................................... 1
11 1530961 Connector (Secondary Lock) ..................................................................... 1
11 1463138 Terminal ..................................................................................................... 4
11 1484377 Plug ............................................................................................................ 2

©2011 HYSTER COMPANY See Service Manual 4-151

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-54)

TRANSMISSION — DUAL SPEED

4-152 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
TRANSMISSION – DUAL SPEED

ITEM PART NO. DESCRIPTION QTY

2085942 Wire Harness (Transmission) .......................................................................... 1
1 ..... Connector Assembly (To RH Chassis Harness) ....................................... 1
1 1623280 Connector ................................................................................................. 1
1 1623281 Connector ................................................................................................. 1
1 1463138 Terminal .................................................................................................... 11
1 1484377 Plug ........................................................................................................... 2
2 1402816 Clip ................................................................................................................. 1
3 1509888 Clip ................................................................................................................. 2
4 ..... Connector Assembly (Temperature) .......................................................... 1
4 1402868 Connector ................................................................................................. 1
4 1323576 Terminal .................................................................................................... 2
5 ..... Connector Assembly (Clutch Forward 1, and 2 Reverse 1) ..................... 1
5 1490242 Connector ................................................................................................. 1
5 1490243 Connector ................................................................................................. 1
5 1330438 Terminal (Socket) ..................................................................................... 2
6 ..... Connector Assembly (Forward/Reverse 1 Pressure) ............................... 1
6 1603021 Connector ................................................................................................. 1
6 1603236 Connector (Secondary Lock) .................................................................. 1
6 1548517 Terminal (Socket) ..................................................................................... 3
6 1548519 Seal ............................................................................................................ 3
7 ..... Connector Assembly (Turbine/Tail Shaft RPM) ......................................... 1
7 1546673 Connector ................................................................................................. 1
7 1323576 Terminal .................................................................................................... 3
8 1509890 Clip ................................................................................................................. 1
9 1402813 Clip ................................................................................................................. 1
10 ..... Connector Assembly (To RH Chassis Harness) ....................................... 1
10 1530960 Connector ................................................................................................. 1
10 1530961 Connector (Secondary Lock) .................................................................. 1
10 1463138 Terminal .................................................................................................... 6

©2011 HYSTER COMPANY See Service Manual 4-153

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-55)

LIGHTS (→ S/N G004V01639D)

4-154 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
LIGHTS (→ S/N G004V01639D)

ITEM PART NO. DESCRIPTION QTY

2073760 Wire Harness (Lights) ......................................................................................... 1
1 ..... Connector Assembly (VSM) ........................................................................... 1
1 1525566 Connector ................................................................................................... 1
1 1484377 Plug ............................................................................................................ 9
1 1330438 Terminal (Socket) ....................................................................................... 3
1 1500913 Connector ................................................................................................... 1
2 ..... Connector Assembly (Chassis Harness) ........................................................ 1
2 1514597 Connector ................................................................................................... 1
2 1484709 Terminal (Pin) ............................................................................................. 4
2 1514598 Connector ................................................................................................... 1
3 ..... Connector Assembly (RH Front Work) ........................................................... 1
3 1490242 Connector ................................................................................................... 1
3 1363886 Terminal (Socket) ....................................................................................... 2
3 1490243 Connector ................................................................................................... 1
4 ..... Connector Assembly (RH Rear Signal) .......................................................... 1
4 1531486 Connector ................................................................................................... 1
4 1330355 Terminal ..................................................................................................... 4
4 1330356 Seal ............................................................................................................ 1
4 1482668 Plug ............................................................................................................ 1
4 930591 Connector ................................................................................................... 1
4 1476108 Wire Seal .................................................................................................... 3
5 1509890 Clip ................................................................................................................. 2
6 ..... Socket Assembly (Strobe) .............................................................................. 1
6 1484557 Connector ................................................................................................... 1
6 1484558 Connector ................................................................................................... 1
6 1463139 Terminal ..................................................................................................... 2
7 ..... Connector Assembly (Rear Work) .................................................................. 1
7 1490242 Connector ................................................................................................... 1
7 1363886 Terminal (Socket) ....................................................................................... 2
7 1490243 Connector ................................................................................................... 1
8 ..... Connector Assembly (LH Rear Signal) .......................................................... 1
8 1531486 Connector ................................................................................................... 1
8 1330355 Terminal ..................................................................................................... 4
8 1330356 Seal ............................................................................................................ 1
8 1482668 Plug ............................................................................................................ 2
8 930591 Connector ................................................................................................... 1
8 1476108 Wire Seal .................................................................................................... 3
9 175944 Heat Shrink ..................................................................................................... AR
10 ..... Connector Assembly (LH Front Work) ........................................................... 1
10 1490242 Connector ................................................................................................... 1
10 1363886 Terminal (Socket) ....................................................................................... 2
10 1490243 Connector ................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 4-155

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-56)

LIGHTS (S/N G004V01640D ↔ 6/2007)

4-156 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
LIGHTS (S/N G004V01640D ↔ 6/2007)

ITEM PART NO. DESCRIPTION QTY

2090084 Wire Harness (Lights) ......................................................................................... 1
1 ..... Connector Assembly (VSM) ........................................................................... 1
1 1525566 Connector ................................................................................................... 1
1 1484377 Plug ............................................................................................................ 9
1 1330438 Terminal (Socket) ....................................................................................... 3
1 1500913 Connector ................................................................................................... 1
2 ..... Connector Assembly (Chassis Harness) ........................................................ 1
2 1514597 Connector ................................................................................................... 1
2 1484709 Terminal (Pin) ............................................................................................. 4
2 1514598 Connector ................................................................................................... 1
3 ..... Connector Assembly (RH Front Work) ........................................................... 1
3 1490242 Connector ................................................................................................... 1
3 1363886 Terminal (Socket) ....................................................................................... 2
3 1490243 Connector ................................................................................................... 1
4 ..... Connector Assembly (RH Rear Signal) .......................................................... 1
4 1531486 Connector ................................................................................................... 1
4 1330355 Terminal ..................................................................................................... 4
4 1330356 Seal ............................................................................................................ 1
4 1482668 Plug ............................................................................................................ 1
4 930591 Connector ................................................................................................... 1
4 1476108 Wire Seal .................................................................................................... 3
5 ..... Connector Assembly (Work Light Resistor) ................................................... 1
5 1514602 Connector ................................................................................................... 1
5 1514603 Connector ................................................................................................... 1
5 1484709 Terminal (Pin) ............................................................................................. 4
6 ..... Socket Assembly (Strobe) .............................................................................. 1
6 1484557 Connector ................................................................................................... 1
6 1484558 Connector ................................................................................................... 1
6 1463139 Terminal ..................................................................................................... 2
7 ..... Connector Assembly (Rear Work) .................................................................. 1
7 1490242 Connector ................................................................................................... 1
7 1363886 Terminal (Socket) ....................................................................................... 2
7 1490243 Connector ................................................................................................... 1
8 ..... Connector Assembly (LH Rear Signal) .......................................................... 1
8 1531486 Connector ................................................................................................... 1
8 1330355 Terminal ..................................................................................................... 4
8 1330356 Seal ............................................................................................................ 1
8 1482668 Plug ............................................................................................................ 2
8 930591 Connector ................................................................................................... 1
8 1476108 Wire Seal .................................................................................................... 3
9 ..... Connector Assembly (LH Front Work) ........................................................... 1
9 1490242 Connector ................................................................................................... 1
9 1363886 Terminal (Socket) ....................................................................................... 2
9 1490243 Connector ................................................................................................... 1
10 1509890 Clip ................................................................................................................. 2

©2011 HYSTER COMPANY See Service Manual 4-157

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-57)

LIGHTS (6/2007 →)

4-158 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
LIGHTS (6/2007 →)

ITEM PART NO. DESCRIPTION QTY

2098385 Wire Harness (Lights) ....................................................................................... 1
1 ..... Connector Assembly (Vehicle System Manager) ...................................... 1
1 1525566 Connector ................................................................................................. 1
1 1500913 Connector ................................................................................................. 1
1 1330438 Terminal (Socket) ..................................................................................... 3
1 1484377 Plug ........................................................................................................... 9
2 ..... Connector Assembly (RH Chassis) ............................................................ 1
2 1514597 Connector ................................................................................................. 1
2 1514598 Connector ................................................................................................. 1
2 1484709 Terminal (Pin) ........................................................................................... 4
3 ..... Connector Assembly (RH Front Work Light) ............................................. 1
3 1490242 Connector ................................................................................................. 1
3 1490243 Connector ................................................................................................. 1
3 1363886 Terminal (Socket) ..................................................................................... 2
4 ..... Connector Assembly (RH Rear Signal) ...................................................... 1
4 1531486 Connector ................................................................................................. 1
4 930591 Connector ................................................................................................. 1
4 1330355 Terminal .................................................................................................... 4
4 1330356 Seal ............................................................................................................ 1
4 1482668 Plug ........................................................................................................... 2
4 1476108 Wire Seal ................................................................................................... 3
5 ..... Connector Assembly (Strobe) ..................................................................... 1
5 1484557 Connector ................................................................................................. 1
5 1484558 Connector ................................................................................................. 1
5 1463139 Terminal .................................................................................................... 2
6 ..... Connector Assembly (Rear Work Light) .................................................... 1
6 1490242 Connector ................................................................................................. 1
6 1490243 Connector ................................................................................................. 1
6 1363886 Terminal (Socket) ..................................................................................... 2
7 ..... Connector Assembly (LH Rear Signal) ...................................................... 1
7 1531486 Connector ................................................................................................. 1
7 930591 Connector ................................................................................................. 1
7 1330355 Terminal .................................................................................................... 4
7 1330356 Seal ............................................................................................................ 1
7 1482668 Plug ........................................................................................................... 2
7 1476108 Wire Seal ................................................................................................... 3
8 ..... Connector Assembly (LH Front Work Light) ............................................. 1
8 1490242 Connector ................................................................................................. 1
8 1490243 Connector ................................................................................................. 1
8 1363886 Terminal (Socket) ..................................................................................... 2
9 275493 Conduit .......................................................................................................... AR
10 275495 Conduit .......................................................................................................... AR
11 175944 Heat Shrink ................................................................................................... AR
12 1509890 Clip ................................................................................................................. 2

©2011 HYSTER COMPANY See Service Manual 4-159

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WIRE HARNESS (FIGURE 4-58)

LOW FUEL SENSOR

4-160 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WIRE HARNESS
LOW FUEL SENSOR

ITEM PART NO. DESCRIPTION QTY

4601522 Wire Harness (Low Fuel Sensor) ........................................................................ 1
1 ..... Connector Assembly (To Engine Harness) .................................................... 1
1 1527273 Connector ................................................................................................... 1
1 1527305 Connector Lock .......................................................................................... 1
1 1402926 Terminal ..................................................................................................... 3
1 1402927 Terminal ..................................................................................................... 5
1 1503334 Seal ............................................................................................................ 3
1 1507571 Seal ............................................................................................................ 5
2 1509888 Clip ................................................................................................................. 1
3 ..... Connector Assembly (Latching Relay) ........................................................... 1
3 1461743 Relay .......................................................................................................... 1
3 1461744 Connector Body ......................................................................................... 1
3 1503088 Lock ............................................................................................................ 1
3 1327164 Seal ............................................................................................................ 1
3 1402912 Terminal ..................................................................................................... 4
3 1323579 Seal ............................................................................................................ 4
4 ..... Connector Assembly (Low LPG Sensor) ........................................................ 1
4 1547629 Connector ................................................................................................... 1
4 1508232 Terminal ..................................................................................................... 3
4 2060555 Wire Seal .................................................................................................... 3
5 ..... Connector Assembly (Air Restriction Sensor Cap) ........................................ 1
5 1465468 Connector ................................................................................................... 1
5 1327164 Seal ............................................................................................................ 2
6 ..... Connector Assembly (Air Restriction Sensor) ................................................ 1
6 1465469 Connector ................................................................................................... 1
6 1323578 Terminal ..................................................................................................... 2
6 1402888 Seal ............................................................................................................ 2
7 ..... Connector Assembly (LPG Lockoff) ............................................................... 1
7 1599337 Connector ................................................................................................... 1
7 1623057 Terminal ..................................................................................................... 2

©2011 HYSTER COMPANY See Service Manual 4-161

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NOTES

4-162 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

5 TRANSMISSION
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 5
TRANSMISSION

DESCRIPTION PAGE

FORWARD CLUTCH
SINGLE SPEED TRANSMISSION (→ S/N G004V02079E) ...................................................................... 5-32
SINGLE SPEED TRANSMISSION (S/N G004V02080E →) ...................................................................... 5-34
FORWARD CLUTCH, HIGH
DUAL SPEED TRANSMISSION (→ S/N G004V02223E) .......................................................................... 5-36
DUAL SPEED TRANSMISSION (S/N G004V02224E →) .......................................................................... 5-38
FORWARD CLUTCH, LOW
DUAL SPEED TRANSMISSION (→ S/N G004V02223E) .......................................................................... 5-40
DUAL SPEED TRANSMISSION (S/N G004V02224E →) .......................................................................... 5-42
REVERSE CLUTCH
DUAL SPEED TRANSMISSION (→ S/N G004V02223E) .......................................................................... 5-48
DUAL SPEED TRANSMISSION (S/N G004V02224E →) .......................................................................... 5-50
SINGLE SPEED TRANSMISSION (→ S/N G004V02079E) ...................................................................... 5-44
SINGLE SPEED TRANSMISSION (S/N G004V02080E →) ...................................................................... 5-46
TORQUE CONVERTER
GM 4.3L, GASOLINE AND LPG ................................................................................................................. 5-4
TRANSMISSION
DUAL SPEED, THREE PIECE HOUSING - SHEET 1 OF 2 (→ S/N G004V02228E (WET BRAKE))
(→ S/N G004V02223E DRY BRAKE) ........................................................................................................ 5-52
DUAL SPEED, THREE PIECE HOUSING - SHEET 2 OF 2 (→ S/N G004V00228E (WET BRAKE))
(→ S/N G004V02223E DRY BRAKE) ........................................................................................................ 5-56
DUAL SPEED, THREE PIECE HOUSING, SHEET 1 OF
2 (S/N G004V02224E ↔ S/N G004V02842E DRY BRAKE)
(S/N G004V02229E ↔ S/N G004V02846E WET BRAKE) ........................................................................ 5-58
DUAL SPEED, THREE PIECE HOUSING, SHEET 2 OF
2 (S/N G004V02224E ↔ S/N G004V02842E DRY BRAKE)
(S/N G004V02229E ↔ S/N G004V02846E WET BRAKE) ........................................................................ 5-61
DUAL SPEED, TWO PIECE HOUSING - SHEET 1 OF 2 (S/N G004V02843E → (DRY BRAKE))
(S/N G004V02847E → (WET BRAKE)) ..................................................................................................... 5-64
DUAL SPEED, TWO PIECE HOUSING - SHEET 2 OF 2 (S/N G004V02843E → (DRY BRAKE))
(S/N G004V02847E → (WET BRAKE)) ..................................................................................................... 5-68
SINGLE SPEED, THREE PIECE HOUSING - SHEET 1 OF 2 (→ S/N G004V02079E EXC. 1698) ......... 5-14
SINGLE SPEED, THREE PIECE HOUSING - SHEET 2 OF 2 (→ S/N G004V02079E EXC. 1698) ......... 5-18
SINGLE SPEED, THREE PIECE HOUSING - SHEET 1 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698)
.................................................................................................................................................................... 5-20
SINGLE SPEED, THREE PIECE HOUSING - SHEET 2 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698)
.................................................................................................................................................................... 5-24
SINGLE SPEED, TWO PIECE HOUSING - SHEET 1 0F 2 (9/2007 →) .................................................... 5-26
SINGLE SPEED, TWO PIECE HOUSING - SHEET 2 0F 2 (9/2007 →) .................................................... 5-30
TRANSMISSION CONTROL VALVE ASSEMBLY
→ PENDING PER ECN 104793 ................................................................................................................ 5-72
PENDING PER ECN 104793 → ................................................................................................................ 5-74
TRANSMISSION COOLING
GM 4.3L, GASOLINE AND LPG, WITH INTERNAL OIL COOLER - BASIC POWERSHIFT
TRANSMISSION (→ S/N G004V04081F) .................................................................................................. 5-6
GM 4.3L, LPG, WITH INTERNAL OIL COOLER - BASIC POWERSHIFT
TRANSMISSION (S/N G004V04082F →) .................................................................................................. 5-8
WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (→ S/N G004V04081F) ............ 5-10
WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (S/N G004V04082F →) ............ 5-12
©2011 HYSTER COMPANY See Service Manual 5-1
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

SECTION 5
TRANSMISSION

DESCRIPTION PAGE

TRANSMISSION MOUNT ............................................................................................................................... 5-3

5-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION MOUNT (FIGURE 5-1)

ITEM PART NO. DESCRIPTION QTY

1 a 1624204 Bracket (Electrical Connector) ............................................................................ 1
1 b 1654415 Bracket (Electrical Connector) ............................................................................ 1
2 1566329 Washer ............................................................................................................... 2
3 2070147 Isolator ............................................................................................................... 2
4 292531 Capscrew ........................................................................................................... 4
5 292683 Lockwasher ....................................................................................................... 4
6 1501276 Bracket ............................................................................................................... 1
7 292685 Lockwasher ......................................................................................................... 1
7 320165 Washer (Alternate Part) .................................................................................... 1
8 293697 Capscrew ........................................................................................................... 1
264134 Loctite ................................................................................................................. AR

FOOTNOTES:
a → 9/2007 b 9/2007 →

©2011 HYSTER COMPANY See Service Manual 5-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TORQUE CONVERTER (FIGURE 5-2)

GM 4.3L, GASOLINE AND LPG

ITEM PART NO. DESCRIPTION QTY

1 1554085 Torque Converter .............................................................................................. 1
2 296420 Washer ............................................................................................................... 6
3 1541921 Capscrew ........................................................................................................... 6
4 360387 Loctite ................................................................................................................ AR

5-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 5-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION COOLING (FIGURE 5-3)

GM 4.3L, GASOLINE AND LPG, WITH INTERNAL OIL COOLER — BASIC POWERSHIFT TRANSMISSION
(→ S/N G004V04081F)

5-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION COOLING
GM 4.3L, GASOLINE AND LPG, WITH INTERNAL OIL COOLER – BASIC POWERSHIFT TRANSMISSION
(→ S/N G004V04081F)

ITEM PART NO. DESCRIPTION QTY

1 1565127 Fitting .................................................................................................................. 2
1 16484 O-Ring ............................................................................................................ 1
1 252729 O-Ring ............................................................................................................ 1
2 1562648 Clip ...................................................................................................................... 3
3 1480237 Nut ...................................................................................................................... 3
4 1629315
4011103 Heat Shield ......................................................................................................... 1
5 1527879 Capscrew ............................................................................................................ 3
6 a 2077747 Hose Assy ........................................................................................................... 1
6 b 2096034 Hose Assy ........................................................................................................... 1
7 2077442 Tube Assy ........................................................................................................... 1
8 1486749 Fitting .................................................................................................................. 1
8 16485 O-Ring ............................................................................................................ 1
8 252729 O-Ring ............................................................................................................ 1
9 1487067 Fitting .................................................................................................................. 1
9 252729 O-Ring ............................................................................................................ 1
9 16485 O-Ring ............................................................................................................ 1
10 1527880 Capscrew ............................................................................................................ 1
11 2077444 Drip Shield .......................................................................................................... 1
12 1632571 Shield .................................................................................................................. 1
13 a 2090114 Hose Assy ........................................................................................................... 1
13 b 2096037 Hose Assy ........................................................................................................... 1

FOOTNOTES:
a → S/N G004V02080E b S/N G004V02081E →

©2011 HYSTER COMPANY See Service Manual 5-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION COOLING (FIGURE 5-4)

GM 4.3L, LPG, WITH INTERNAL OIL COOLER — BASIC POWERSHIFT TRANSMISSION
(S/N G004V04082F →)

5-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION COOLING
GM 4.3L, LPG, WITH INTERNAL OIL COOLER – BASIC POWERSHIFT TRANSMISSION
(S/N G004V04082F →)

ITEM PART NO. DESCRIPTION QTY

1 1565127 Fitting .................................................................................................................. 1
1 16484 O-Ring ............................................................................................................ 1
1 252729 O-Ring ............................................................................................................ 1
2 1562648 Clip ...................................................................................................................... 3
3 1480237 Nut ...................................................................................................................... 3
4 1629315
4011103 Heat Shield ......................................................................................................... 1
5 1527879 Capscrew ............................................................................................................ 2
6 2077747 Hose Assy ........................................................................................................... 1
6 b 2096034 Hose Assy ........................................................................................................... 1
6 c 2107524 Hose ................................................................................................................... 1
6 e 4603957 Hose ................................................................................................................... 1
7 b 2077442 Tube Assy ........................................................................................................... 1
7 d 2109874 Tube Assy ........................................................................................................... 1
8 a 1486749 Fitting .................................................................................................................. 1
8 16485 O-Ring ............................................................................................................ 1
8 252729 O-Ring ............................................................................................................ 1
8 e 222504 Fitting .................................................................................................................. 1
8 16485 O-Ring ............................................................................................................ 1
9 b 1487067 Fitting .................................................................................................................. 1
9 b 252729 O-Ring ............................................................................................................ 1
9 b 16485 O-Ring ............................................................................................................ 1
9 d 222512 Fitting .................................................................................................................. 1
9 d 16485 O-Ring ............................................................................................................ 1
10 1527880 Capscrew ............................................................................................................ 1
11 2077444 Drip Shield .......................................................................................................... 1
12 1632571 Shield .................................................................................................................. 1
13 2090114 Hose Assy ........................................................................................................... 1
13 b 2096037 Hose Assy ........................................................................................................... 1
13 d 2109869 Hose ................................................................................................................... 1
14 d 1691525 Adapter ............................................................................................................... 1
14 16485 O-Ring ............................................................................................................ 1
15 d 1673198 Fitting .................................................................................................................. 1
15 16484 O-Ring ............................................................................................................ 1
16 d 130845 Clamp ................................................................................................................. 4
17 d 2109875 Tube Assy ........................................................................................................... 1

FOOTNOTES:
a → PENDING PER ECN 106121 d S/N G004V04082F →
b → S/N G004V04082F e PENDING PER ECN 106121 →
c S/N G004V04082F ↔ PENDING PER ECN
106121

©2011 HYSTER COMPANY See Service Manual 5-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION COOLING (FIGURE 5-5)

WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (→ S/N G004V04081F)

5-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION COOLING
WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (→ S/N G004V04081F)

ITEM PART NO. DESCRIPTION QTY

1 a 2075846 Hose Assy ........................................................................................................... 1
1 b 2095659 Hose Assy ........................................................................................................... 1
2 1527879 Capscrew ............................................................................................................ 2
3 1487067 Fitting .................................................................................................................. 1
3 252729 O-Ring ............................................................................................................ 1
3 16485 O-Ring ............................................................................................................ 1
4 1486749 Fitting .................................................................................................................. 3
4 16485 O-Ring ............................................................................................................ 1
5 1480237 Nut ...................................................................................................................... 2
6 1562648 Clip ...................................................................................................................... 1
7 2086527 Shield .................................................................................................................. 1
8 a 2077746 Hose Assy ........................................................................................................... 1
8 b 2095659 Hose Assy ........................................................................................................... 1

FOOTNOTES:
a → S/N G004V02080E b S/N G004V02081E →

©2011 HYSTER COMPANY See Service Manual 5-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION COOLING (FIGURE 5-6)

WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (S/N G004V04082F →)

5-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION COOLING
WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (S/N G004V04082F →)

ITEM PART NO. DESCRIPTION QTY

1 2075846 Hose Assy ........................................................................................................... 1
1 a 2095659 Hose Assy ........................................................................................................... 1
1 b 2109871 Hose ................................................................................................................... 1
1 2109665 Hose Assy (Alternate Part) ................................................................................. 1
2 1527879 Capscrew ............................................................................................................ 2
3 a 1487067 Fitting .................................................................................................................. 1
3 a 252729 O-Ring ............................................................................................................ 1
3 a 16485 O-Ring ............................................................................................................ 1
3 b 222512 Fitting .................................................................................................................. 1
3 b 16485 O-Ring ............................................................................................................ 1
4 1486749 Fitting .................................................................................................................. 3
4 16485 O-Ring ............................................................................................................ 1
5 1480237 Nut ...................................................................................................................... 2
6 130845 Clamp ................................................................................................................. 4
7 2086527 Shield .................................................................................................................. 1
8 2077746 Hose Assy ........................................................................................................... 1
8 a 2096035 Hose Assy ........................................................................................................... 1
8 b 2109870 Hose ................................................................................................................... 1
9 b 17223 Fitting .................................................................................................................. 1
10 b 1691525 Adapter ............................................................................................................... 1
11 b 2109875 Tube Assy ........................................................................................................... 1

FOOTNOTES:
a → S/N G004V04082F b S/N G004V04082F →

©2011 HYSTER COMPANY See Service Manual 5-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-7)

SINGLE SPEED, THREE PIECE HOUSING — SHEET 1 OF 2 (→ S/N G004V02079E EXC. 1698)

5-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
SINGLE SPEED, THREE PIECE HOUSING – SHEET 1 OF 2 (→ S/N G004V02079E EXC. 1698)

ITEM PART NO. DESCRIPTION QTY

a 1557709 Transmission Assy (Single Speed) (Without Boost) ........................................... 1
b 1557711 Transmission Assy (Single Speed) (With Boost) ................................................ 1
1 a 1613695 Hydraulic Control Valve (FFigure 5-29)......................................................... 1
1 b 1611835 Hydraulic Control Valve (FFigure 5-29)......................................................... 1
2 292509 Capscrew ....................................................................................................... 11
3 320157 Washer ........................................................................................................... 12
4 1570360 Gasket ............................................................................................................ 1
5 233693 Fitting .............................................................................................................. 1
5 16485 O-Ring ........................................................................................................ 1
6 1624505 Housing (Transmission) ................................................................................. 1
7 1547447 Oil Seal ........................................................................................................... 1
8 1529874 Yoke (Fixed) ................................................................................................... 1
9 18595 Capscrew ....................................................................................................... 1
10 15158 Washer ........................................................................................................... 1
11 15135 Washer ........................................................................................................... 1
12 1550576 Gasket (Cover to Transmission Housing) ...................................................... 1
13 1524373 Clutch Pack (Reverse) (FFigure 5-19).......................................................... 1
14 1524372 Clutch Pack (Forward) (FFigure 5-13).......................................................... 1
15 1541231 Sensor (Input Speed, TISS) ........................................................................... 1
16 1541232 Sensor (Output Speed, TOSS) ....................................................................... 1
17 292680 Washer ........................................................................................................... 2
18 292500 Capscrew ....................................................................................................... 2
19 86229 Seal ................................................................................................................ 1
20 43209 Ball Bearing .................................................................................................... 1
21 1565135 Gear (Output) ................................................................................................. 1
22 1516851 Spacer ............................................................................................................ 1
23 1525686 Nut .................................................................................................................. 1
24 213099 Snap Ring ....................................................................................................... 1
25 44309 Ball Bearing .................................................................................................... 1
26 1624501 Housing (Front Cover) .................................................................................... 1
27 1550573 Gasket (Torque Converter Housing to Cover) ................................................ 1
28 388049
292682 Lockwasher .................................................................................................... 24
29 292516 Capscrew ....................................................................................................... 4
30 334560 Magnet ........................................................................................................... 1
31 1624415 Cover (Pump Drive) ........................................................................................ 1
32 16682 O-Ring ............................................................................................................ 1
33 1494750 Chain (Drive Pump) ........................................................................................ 1
34 1544218 Sealing Ring ................................................................................................... 1
35 44310 Ball Bearing .................................................................................................... 1
36 1624401 Dipstick ........................................................................................................... 1
37 1624405 Fitting .............................................................................................................. 1
37 216590 Fitting ......................................................................................................... 1
38 16485 O-Ring ........................................................................................................ 1
39 2021389 Breather .......................................................................................................... 1
40 1624407 Fitting .............................................................................................................. 1
40 14603 Plug ............................................................................................................ 1
41 16486 O-Ring ........................................................................................................ 1
42 303100 Roll Pin ........................................................................................................... 4
43 1553270 Snubber .......................................................................................................... 2

©2011 HYSTER COMPANY See Service Manual 5-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION
SINGLE SPEED, THREE PIECE HOUSING – SHEET 1 OF 2 (→ S/N G004V02079E EXC. 1698)

ITEM PART NO. DESCRIPTION QTY

44 1487067 Fitting .............................................................................................................. 1
44 252729 O-Ring ........................................................................................................ 1
44 16485 O-Ring ........................................................................................................ 1
45 303150 Dowel ............................................................................................................. 4
46 1553475 O-Ring ............................................................................................................ 1
47 c 222444 Fitting .............................................................................................................. 1
47 16486 O-Ring ........................................................................................................ 1
47 d 233683 Fitting .............................................................................................................. 1
47 16487 O-Ring ........................................................................................................ 1
48 235691 Fitting .............................................................................................................. 7
48 16484 O-Ring ........................................................................................................ 1
49 a 1612918 Spring (Regulator) .......................................................................................... 1
50 b 1612917 Spring (Regulator) .......................................................................................... 1
51 b 1612916 Spool (Regulator) ........................................................................................... 1
52 1359458 Capscrew ....................................................................................................... 16
53 1553403 O-Ring ............................................................................................................ 4
54 2070263 Pressure Transducer ...................................................................................... 1

FOOTNOTES:
a Dry Brake c → S/N G004V01515D
b Wet Brake d S/N G004V01516D →

5-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 5-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-8)

SINGLE SPEED, THREE PIECE HOUSING — SHEET 2 OF 2 (→ S/N G004V02079E EXC. 1698)

5-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
SINGLE SPEED, THREE PIECE HOUSING – SHEET 2 OF 2 (→ S/N G004V02079E EXC. 1698)

ITEM PART NO. DESCRIPTION QTY

a 1557709 Transmission Assy (Single Speed) (Without Boost) ........................................... 1
b 1557711 Transmission Assy (Single Speed) (With Boost) ................................................ 1
1 1550566 Converter Housing (Torque Convertor) .......................................................... 1
2 145481 O-Ring ............................................................................................................ 1
3 1544217 Oil Seal (Torque Converter) ........................................................................... 1
4 1544216 Bearing ........................................................................................................... 1
5 1541556 Sprocket ......................................................................................................... 1
6 1525677 Stator .............................................................................................................. 1
6 1516826 Bushing ...................................................................................................... 1
7 1566169 Cover .............................................................................................................. 1
8 136985 Capscrew ....................................................................................................... 4
9 1550571 Screen (Suction) ............................................................................................. 1
10 1550572 Spring (Suction Screen) ................................................................................. 1
11 1515654 Temperature Sensor ...................................................................................... 1
12 188210 Fitting .............................................................................................................. 1
12 16983 O-Ring ........................................................................................................ 1
13 292500 Capscrew ....................................................................................................... 2
14 292680 Washer ........................................................................................................... 2
15 1550567 Cover Plate (Torque Convertor Housing) ....................................................... 1
16 43209 Ball Bearing .................................................................................................... 1
17 1550586 Sprocket (Driven) ........................................................................................... 1
18 44307 Ball Bearing .................................................................................................... 1
19 a 1552853 Pump (27.0 CC/REV) ..................................................................................... 1
19 b 2076519 Pump (27.0 CC/Aux) ...................................................................................... 1
19 a 1623836 O-Ring ........................................................................................................ 1
19 b 1623837 O-Ring ........................................................................................................ 1
20 1653815 Gasket (Charge Pump) .................................................................................. 1
21 292681 Lockwasher .................................................................................................... 6
22 296022 Capscrew ....................................................................................................... 4
23 2075558 Transmission Filter ......................................................................................... 1
24 1558515 Fitting .............................................................................................................. 1
25 320161 Washer ........................................................................................................... 1
26 292683 Lockwasher .................................................................................................... 1
27 292526 Capscrew ....................................................................................................... 1

FOOTNOTES:
a Dry Brake b Wet Brake

©2011 HYSTER COMPANY See Service Manual 5-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-9)

SINGLE SPEED, THREE PIECE HOUSING — SHEET 1 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698)

5-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
SINGLE SPEED, THREE PIECE HOUSING – SHEET 1 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698)

ITEM PART NO. DESCRIPTION QTY

a 1646877 Transmission Assy (Single Speed without Boost) .............................................. 1
b 1646878 Transmission Assy (Single Speed with Boost) ................................................... 1
1 b 1613695 Hydraulic Control Valve (FFigure 5-29)......................................................... 1
1 a 1611835 Hydraulic Control Valve (FFigure 5-29)......................................................... 1
2 292509 Capscrew ....................................................................................................... 11
3 320157 Washer ........................................................................................................... 12
4 1570360 Gasket ............................................................................................................ 1
5 233693 Fitting .............................................................................................................. 1
5 16485 O-Ring ........................................................................................................ 1
6 1639069 Transmission Housing .................................................................................... 1
7 1547447 Oil Seal ........................................................................................................... 1
8 1529874 Yoke (Fixed) ................................................................................................... 1
9 18595 Capscrew ....................................................................................................... 1
10 15158 Washer ........................................................................................................... 1
11 15135 Washer ........................................................................................................... 1
12 1550576 Gasket (Cover to Transmission Housing) ...................................................... 1
13 1646888 Clutch Pack (Reverse) (FFigure 5-20).......................................................... 1
14 1646887 Clutch Pack (Forward) (FFigure 5-14).......................................................... 1
15 1541231 Sensor (Input Speed, TISS) ........................................................................... 1
16 1541232 Sensor (Output Speed, TOSS) ....................................................................... 1
17 292680 Washer ........................................................................................................... 2
18 292500 Capscrew ....................................................................................................... 2
19 86229 Seal ................................................................................................................ 1
20 43209 Ball Bearing .................................................................................................... 1
21 1565135 Gear (Output) ................................................................................................. 1
22 1516851 Spacer ............................................................................................................ 1
23 1525686 Nut .................................................................................................................. 1
24 213099 Snap Ring ....................................................................................................... 1
25 44309 Ball Bearing .................................................................................................... 1
26 1624501 Housing (Front Cover) .................................................................................... 1
27 1550573 Gasket (Torque Converter Housing to Cover) ................................................ 1
28 388049
292682 Lockwasher .................................................................................................... 24
29 292516 Capscrew ....................................................................................................... 4
30 334560 Magnet ........................................................................................................... 1
31 1624415 Cover (Pump Drive) ........................................................................................ 1
32 16682 O-Ring ............................................................................................................ 1
33 1494750 Chain (Drive Pump) ........................................................................................ 1
34 1544218 Sealing Ring ................................................................................................... 1
35 44310 Ball Bearing .................................................................................................... 1
36 1624401 Dipstick ........................................................................................................... 1
37 1624405 Fitting .............................................................................................................. 1
37 216590 Fitting ......................................................................................................... 1
38 16485 O-Ring ........................................................................................................ 1
39 1632741 Breather .......................................................................................................... 1
39 16486 O-Ring ........................................................................................................ 1
40 1640573 Fitting .............................................................................................................. 1
40 16484 O-Ring ........................................................................................................ 1
41 1624414 Baffle .......................................................................................................... 1
42 303100 Roll Pin ........................................................................................................... 4

©2011 HYSTER COMPANY See Service Manual 5-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION
SINGLE SPEED, THREE PIECE HOUSING – SHEET 1 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698)

ITEM PART NO. DESCRIPTION QTY

43 1553270 Snubber .......................................................................................................... 2
44 1486555 Fitting .............................................................................................................. 1
44 252729 O-Ring ........................................................................................................ 1
44 16485 O-Ring ........................................................................................................ 1
45 303150 Dowel ............................................................................................................. 4
46 1553475 O-Ring ............................................................................................................ 1
47 233683 Fitting .............................................................................................................. 1
47 16487 O-Ring ........................................................................................................ 1
48 235691 Fitting .............................................................................................................. 6
48 16484 O-Ring ........................................................................................................ 1
49 b 1612918 Spring (Regulator) .......................................................................................... 1
50 a 1612917 Spring (Regulator) .......................................................................................... 1
51 a 1612916 Spool (Regulator) ........................................................................................... 1
52 1359458 Capscrew ....................................................................................................... 16
53 1553403 O-Ring ............................................................................................................ 4
54 2070263 Pressure Transducer ...................................................................................... 1

FOOTNOTES:
a Dry Brake b Wet Brake

5-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 5-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-10)

SINGLE SPEED, THREE PIECE HOUSING — SHEET 2 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698)

5-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
SINGLE SPEED, THREE PIECE HOUSING – SHEET 2 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698)

ITEM PART NO. DESCRIPTION QTY

a 1646877 Transmission Assy (Single Speed without Boost) .............................................. 1
b 1646878 Transmission Assy (Single Speed with Boost) ................................................... 1
1 1624504 Converter Housing (Torque Converter) .......................................................... 1
2 145481 O-Ring ............................................................................................................ 1
3 1544217 Oil Seal (Torque Converter) ........................................................................... 1
4 1544216 Bearing ........................................................................................................... 1
5 1541556 Sprocket (Driving) ........................................................................................... 1
6 1525677 Stator .............................................................................................................. 1
6 1516826 Bushing ...................................................................................................... 1
7 1566169 Cover .............................................................................................................. 1
8 136985 Capscrew ....................................................................................................... 4
9 1550571 Screen (Suction) ............................................................................................. 1
10 1550572 Spring (Suction Screen) ................................................................................. 1
11 1515654 Temperature Sensor ...................................................................................... 1
12 188210 Fitting .............................................................................................................. 1
12 16983 O-Ring ........................................................................................................ 1
13 292500 Capscrew ....................................................................................................... 2
14 292680 Washer ........................................................................................................... 2
15 1550567 Cover Plate (Torque Converter Housing) ....................................................... 1
16 43209 Ball Bearing .................................................................................................... 1
17 1529890 Sprocket (Driven) ........................................................................................... 1
18 44307 Ball Bearing .................................................................................................... 1
19 b 2076519 Pump (27.0 CC/Aux) ...................................................................................... 1
19 a 1552853 Pump (27.0 CC/REV) ..................................................................................... 1
19 a 1623836 O-Ring ........................................................................................................ 1
20 1653815 Gasket (Charge Pump) .................................................................................. 1
21 292681 Lockwasher .................................................................................................... 6
22 296022 Capscrew ....................................................................................................... 4
23 2075558 Transmission Filter ......................................................................................... 1
24 1558515 Fitting .............................................................................................................. 1
25 320161 Washer ........................................................................................................... 1
26 292683 Lockwasher .................................................................................................... 1
27 292526 Capscrew ....................................................................................................... 1

FOOTNOTES:
a Dry Brake b Wet Brake

©2011 HYSTER COMPANY See Service Manual 5-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-11)

SINGLE SPEED, TWO PIECE HOUSING — SHEET 1 0F 2 (9/2007 →)

5-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
SINGLE SPEED, TWO PIECE HOUSING – SHEET 1 0F 2 (9/2007 →)

ITEM PART NO. DESCRIPTION QTY

b 1638795 Transmission Assy (Single Speed Dry Brake) (Without Boost) Transmission: S/
N T123M0002792=> ........................................................................................... 1
c 1703472 Transmission Assy .............................................................................................. 1
a 1638796 Transmission Assy (Single Speed Wet Brake) (With Boost) Transmission: S/N
T126M0001774=> .............................................................................................. 1
c 1703473 Transmission Assy .............................................................................................. 1
1 188210 Fitting .............................................................................................................. 1
2 1550572 Spring ............................................................................................................. 1
3 1627465 Screen ............................................................................................................ 1
4 1515654 Temperature Sensor ...................................................................................... 1
5 1636644 Converter Housing (Torque Converter) .......................................................... 1
6 1632741 Breather .......................................................................................................... 1
7 1653815 Gasket ............................................................................................................ 2
8 1640573 Fitting .............................................................................................................. 1
9 1624406 Dipstick Tube .................................................................................................. 1
10 1624401 Dipstick ........................................................................................................... 1
11 1622888 Cover (Converter Housing) ............................................................................ 1
11 1699141 Cover Plate (Converter Housing) (Alternate Part) .......................................... 1
12 292681 Lockwasher .................................................................................................... 6
13 2075558 Transmission Filter ......................................................................................... 1
13 4020588 Transmission Filter (Alternate Part) .................................................................... 1
14 1558515 Fitting .............................................................................................................. 1
15 136681 Capscrew ....................................................................................................... 2
16 1612918 Spring ............................................................................................................. 1
17 1612916 Spool .............................................................................................................. 1
18 235691 Fitting .............................................................................................................. 4
19 2070263 Pressure Transducer ...................................................................................... 1
20 303100 Roll Pin ........................................................................................................... 4
21 145481 O-Ring ............................................................................................................ 1
22 1553403 O-Ring ............................................................................................................ 2
23 1544217 Oil Seal (Torque Converter) ........................................................................... 1
24 1541556 Sprocket ......................................................................................................... 1
25 1544218 Sealing Ring ................................................................................................... 1
26 1544216 Bearing ........................................................................................................... 1
27 44307 Ball Bearing .................................................................................................... 1
28 1529890 Sprocket ......................................................................................................... 1
29 43209 Ball Bearing .................................................................................................... 2
30 1494750 Chain (Drive Pump) ........................................................................................ 1
31 1615804 Snubber .......................................................................................................... 2
32 334560 Magnet ........................................................................................................... 1
33 296022 Capscrew ....................................................................................................... 4
34 1624408 Shield (Upper) ................................................................................................ 1
35 292680 Washer ........................................................................................................... 6
36 148962 Capscrew ....................................................................................................... 4
37 292500 Capscrew ....................................................................................................... 2
38 1550567 Cover Plate ..................................................................................................... 1
39 1525686 Nut .................................................................................................................. 1
40 1636645 Spacer ........................................................................................................ 1
41 213099 Snap Ring ....................................................................................................... 1
42 44309 Ball Bearing .................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 5-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION
SINGLE SPEED, TWO PIECE HOUSING – SHEET 1 0F 2 (9/2007 →)

ITEM PART NO. DESCRIPTION QTY

43 1547447 Oil Seal ........................................................................................................... 1
44 1622887 Baffle .............................................................................................................. 1
45 1627453 Shield (Lower) ................................................................................................ 1
46 1552853 Pump (Dry Brake) ........................................................................................... 1
46 2076519 Pump (Wet Brake) .......................................................................................... 1
46 1623836 O-Ring ........................................................................................................ 1
46 1623837 O-Ring ........................................................................................................ 1
47 1654004 Yoke ............................................................................................................... 1
48 d 1487067 Fitting .................................................................................................................. 1

FOOTNOTES:
a S/N G004V02845E ↔ S/N G004V04081F c S/N G004V04082F →
b S/N G004V02845E ↔ S/N G004V04081F EXC. d PENDING PER ECN 10481702 →
02874-02877, 02879-02880, 02882-02883,
02891, 02894-02896, 02898, 02901-02902

5-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 5-29

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-12)

SINGLE SPEED, TWO PIECE HOUSING — SHEET 2 0F 2 (9/2007 →)

5-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
SINGLE SPEED, TWO PIECE HOUSING – SHEET 2 0F 2 (9/2007 →)

ITEM PART NO. DESCRIPTION QTY

b 1638795 Transmission Assy (Single Speed Dry Brake) (Without Boost) Transmission:
T123M0002792 => ............................................................................................. 1
c 1703472 Transmission Assy .............................................................................................. 1
a 1638796 Transmission Assy (Single Speed Wet Brake) (With Boost) Transmission:
T126M0001744 => ............................................................................................. 1
c 1703473 Transmission Assy .............................................................................................. 1
1 44310 Ball Bearing .................................................................................................... 1
2 136985 Capscrew ....................................................................................................... 4
3 388049
292682 Lockwasher .................................................................................................... 25
4 1525677 Stator .............................................................................................................. 1
5 16682 O-Ring ............................................................................................................ 1
6 1638799 Carrier ............................................................................................................ 1
7 292516 Capscrew ....................................................................................................... 4
8 1553403 O-Ring ............................................................................................................ 2
9 1654651 Flange Head Capscrew .................................................................................. 1
10 86229 Seal ................................................................................................................ 1
11 1638793 Gear (Output) ................................................................................................. 1
12 1646887 Clutch Pack .................................................................................................... 1
13 1646888 Clutch Pack .................................................................................................... 1
14 1636640 Gasket ............................................................................................................ 1
15 222443 Fitting .............................................................................................................. 1
16 233693 Fitting .............................................................................................................. 2
17 1541232 Sensor (Output Speed, TOSS) ....................................................................... 1
18 292680 Washer ........................................................................................................... 2
19 292500 Capscrew ....................................................................................................... 2
20 292509 Capscrew ....................................................................................................... 11
21 320157 Washer ........................................................................................................... 1
22 1570360 Gasket ............................................................................................................ 1
23 1541231 Sensor (Input Speed, TISS) ........................................................................... 1
24 235691 Fitting .............................................................................................................. 4
25 303150 Dowel ............................................................................................................. 4
26 1652575 Bracket ........................................................................................................... 1
27 292515 Capscrew ....................................................................................................... 15
28 222444 Fitting .............................................................................................................. 1
29 1636643 Transmission Housing .................................................................................... 1
30 1665205 Valve (Low Pressure) (Wet Brake) (FFigure 5-30)........................................ 1
30 1665204 Valve (High Pressure) (Dry Brake) (FFigure 5-30)........................................ 1

FOOTNOTES:
a S/N G004V02835E ↔ S/N G004V04081F c S/N G004V04082F →
b S/N G004V02845E ↔ S/N G004V04081F EXC.
02874-02877, 02879-02880, 02882-02883,
02891, 02894-02896, 02898, 02901-02902

©2011 HYSTER COMPANY See Service Manual 5-31

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FORWARD CLUTCH (FIGURE 5-13)

SINGLE SPEED TRANSMISSION (→ S/N G004V02079E)

5-32 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FORWARD CLUTCH
SINGLE SPEED TRANSMISSION (→ S/N G004V02079E)

ITEM PART NO. DESCRIPTION QTY

1524372 Clutch Pack ......................................................................................................... 1
1 ..... Ring Seal ........................................................................................................ 3
2 1581116 Ball Bearing .................................................................................................... 2
3 1581104 Shaft ............................................................................................................... 1
4 ..... Ring Seal ........................................................................................................ 1
5 ..... Ring Seal ........................................................................................................ 1
6 1552525 Piston ............................................................................................................. 1
7 1581108 Spring ............................................................................................................. 1
8 1581098 Spring ............................................................................................................. 1
9 1581099 Spring Guide .................................................................................................. 1
10 1581100 Snap Ring ....................................................................................................... 1
11 ..... Conical Plate .................................................................................................. 1
12 ..... Friction Plate .................................................................................................. 5
13 ..... Separator Plate .............................................................................................. 4
14 1543094 Pressure Plate (5.8 mm) ................................................................................ 1
14 1537449 Pressure Plate (6.0 mm) ................................................................................ 1
14 1543096 Pressure Plate (5.6 mm) ................................................................................ 1
14 1543097 Pressure Plate (5.4 mm) ................................................................................ 1
14 1543098 Pressure Plate (5.2 mm) ................................................................................ 1
15 1537450 Snap Ring ....................................................................................................... 1
16 124603 Ball Bearing .................................................................................................... 1
17 1581107 Snap Ring ....................................................................................................... 2
18 1581117 Spacer ............................................................................................................ 1
19 ..... Seal ................................................................................................................ 1
20 1595427 Gear ............................................................................................................... 1
21 1581106 Snap Ring ....................................................................................................... 1
22 43207 Ball Bearing .................................................................................................... 1
1595426 Kit-Clutch Pack Plates/Seals (Includes Items 1, 4-5, 11-13, 19) ........................ 1
1543102 Kit-Clutch Pack Plates (Includes Items 11-13) ................................................... 1
1595425 Kit-Clutch Pack Seals (Includes Items 1, 4-5, 19) .............................................. 1

©2011 HYSTER COMPANY See Service Manual 5-33

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FORWARD CLUTCH (FIGURE 5-14)

SINGLE SPEED TRANSMISSION (S/N G004V02080E →)

5-34 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FORWARD CLUTCH
SINGLE SPEED TRANSMISSION (S/N G004V02080E →)

ITEM PART NO. DESCRIPTION QTY

1646887 Clutch Pack ......................................................................................................... 1
1 ..... Ring Seal ........................................................................................................ 3
2 43207 Ball Bearing .................................................................................................... 3
3 1651760 Shaft ............................................................................................................... 1
3 4025492 Shaft (Alternate Part) ...................................................................................... 1
4 ..... Ring Seal ........................................................................................................ 1
5 ..... Ring Seal ........................................................................................................ 1
6 2085129 Piston ............................................................................................................. 1
7 1581108 Spring ............................................................................................................. 1
8 1581098 Spring ............................................................................................................. 1
9 1581099 Spring Guide .................................................................................................. 1
10 1581100 Snap Ring ....................................................................................................... 1
11 ..... Conical Plate .................................................................................................. 1
12 ..... Friction Plate .................................................................................................. 8
13 ..... Separator Plate .............................................................................................. 7
14 1537449 Pressure Plate (6.0 mm) ................................................................................ 1
15 ..... O-Ring ............................................................................................................ 1
16 1537450 Snap Ring ....................................................................................................... 1
17 124603 Ball Bearing .................................................................................................... 1
18 1581107 Snap Ring ....................................................................................................... 2
19 1651761 Clutch Gear .................................................................................................... 1
20 1581106 Snap Ring ....................................................................................................... 1
1652272 Kit-Repair ............................................................................................................ 1
1571673 Kit-Clutch Pack Plates (Clutch Pack Plates) (Includes Items 11-13) .................. 1
1595425 Kit-Clutch Pack Seals (Includes Items 1, 4-5, 15) .............................................. 1

©2011 HYSTER COMPANY See Service Manual 5-35

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FORWARD CLUTCH, HIGH (FIGURE 5-15)

DUAL SPEED TRANSMISSION (→ S/N G004V02223E)

5-36 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FORWARD CLUTCH, HIGH

DUAL SPEED TRANSMISSION (→ S/N G004V02223E)

ITEM PART NO. DESCRIPTION QTY

1524371 Clutch Pack (Forward-High) ............................................................................... 1
1 ..... Seal ................................................................................................................ 2
2 1537455 Ball Bearing .................................................................................................... 1
3 1639862 Shaft ............................................................................................................... 1
4 ..... Seal ................................................................................................................ 1
5 ..... Seal ................................................................................................................ 1
6 2085129 Piston ............................................................................................................. 1
7 1581108 Spring ............................................................................................................. 1
8 1581098 Spring ............................................................................................................. 1
9 1581099 Spring Guide .................................................................................................. 1
10 1581100 Snap Ring ....................................................................................................... 1
11 ..... Conical Plate .................................................................................................. 1
12 ..... Friction Plate .................................................................................................. 9
13 ..... Separator Plate .............................................................................................. 8
14 1537449 Pressure Plate (6.0 mm) ................................................................................ 1
15 1537450 Snap Ring ....................................................................................................... 1
16 124603 Ball Bearing .................................................................................................... 1
17 1581107 Snap Ring ....................................................................................................... 1
18 1581105 Spacer ............................................................................................................ 1
19 ..... Seal ................................................................................................................ 1
20 1639864 Gear ............................................................................................................... 1
21 43207 Ball Bearing .................................................................................................... 2
22 1581106 Snap Ring ....................................................................................................... 1
1595426 Kit-Clutch Pack Plates/Seals (Includes Items 1, 4-5, 11-13, 19) ........................ 1
1543102 Kit-Clutch Pack Plates (Includes Items 11-13) ................................................... 1
1595425 Kit-Clutch Pack Seals (Includes Items 1, 4-5, 19) .............................................. 1

©2011 HYSTER COMPANY See Service Manual 5-37

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FORWARD CLUTCH, HIGH (FIGURE 5-16)

DUAL SPEED TRANSMISSION (S/N G004V02224E →)

5-38 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FORWARD CLUTCH, HIGH

DUAL SPEED TRANSMISSION (S/N G004V02224E →)

ITEM PART NO. DESCRIPTION QTY

1646885 Clutch Pack (Forward-High) ............................................................................ 1
1 ..... Seal ................................................................................................................ 2
2 1651753 Ball Bearing .................................................................................................. 2
3 1639862 Shaft ............................................................................................................... 1
3 4025491 Shaft (Alternate Part) ................................................................................... 1
4 ..... Seal ................................................................................................................ 1
5 ..... Seal ................................................................................................................ 1
6 2085129 Piston ............................................................................................................ 1
7 1581108 Spring ............................................................................................................ 1
8 1581098 Spring ............................................................................................................ 1
9 1581099 Spring Guide ................................................................................................. 1
10 1581100 Snap Ring ...................................................................................................... 1
11 ..... Conical Plate ................................................................................................. 1
12 ..... Friction Plate ................................................................................................. 9
13 ..... Separator Plate ............................................................................................. 8
14 1537449 Pressure Plate (6.0 mm) ............................................................................... 1
15 1537450 Snap Ring ...................................................................................................... 1
16 124603 Ball Bearing .................................................................................................. 1
17 1581107 Snap Ring ...................................................................................................... 1
18 ..... Seal ................................................................................................................ 1
18 1581105 Spacer ............................................................................................................ 1
19 1639864 Gear ............................................................................................................... 1
20 43207 Ball Bearing .................................................................................................. 1
21 1581106 Snap Ring ....................................................................................................... 1
1652269 Kit-Clutch Pack Plates/Seals (Includes Items 1, 4-5, 11-13, 18) ........................ 1
1651852 Kit-Clutch Pack Plates (Includes Items 11-13) ............................................... 1
1595425 Kit-Clutch Pack Seals (Includes Items 1, 4-5, 18) .......................................... 1

©2011 HYSTER COMPANY See Service Manual 5-39

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FORWARD CLUTCH, LOW (FIGURE 5-17)

DUAL SPEED TRANSMISSION (→ S/N G004V02223E)

5-40 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FORWARD CLUTCH, LOW

DUAL SPEED TRANSMISSION (→ S/N G004V02223E)

ITEM PART NO. DESCRIPTION QTY

1524355 Clutch Pack (Input/Forward-Low) ....................................................................... 1
1 ..... Seal ................................................................................................................ 3
2 43207 Ball Bearing .................................................................................................... 2
3 1639865 Shaft ............................................................................................................... 1
4 ..... Seal ................................................................................................................ 1
5 ..... Seal ................................................................................................................ 1
6 2085129 Piston ............................................................................................................. 1
7 1581108 Spring ............................................................................................................. 1
8 1581098 Spring ............................................................................................................. 1
9 1581099 Spring Guide .................................................................................................. 1
10 1581100 Snap Ring ....................................................................................................... 1
11 ..... Conical Plate .................................................................................................. 1
12 ..... Friction Plate .................................................................................................. 9
13 ..... Separator Plate .............................................................................................. 8
14 1537449 Pressure Plate (6.0 mm) ................................................................................ 1
15 1537450 Snap Ring ....................................................................................................... 1
16 124603 Ball Bearing .................................................................................................... 1
17 1581107 Snap Ring ....................................................................................................... 1
18 1581105 Spacer ............................................................................................................ 1
19 ..... Seal ................................................................................................................ 1
20 1595428 Gear ............................................................................................................... 1
21 1537459 Snap Ring ....................................................................................................... 1
1595426 Kit-Clutch Pack Plates/Seals (Includes Items 1, 4-5, 11-13, 19) ........................ 1
1543102 Kit-Clutch Pack Plates (Includes Items 11-13) ................................................... 1
1595425 Kit-Clutch Pack Seals (Includes Items 1, 4-5, 19) .............................................. 1

©2011 HYSTER COMPANY See Service Manual 5-41

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FORWARD CLUTCH, LOW (FIGURE 5-18)

DUAL SPEED TRANSMISSION (S/N G004V02224E →)

5-42 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FORWARD CLUTCH, LOW

DUAL SPEED TRANSMISSION (S/N G004V02224E →)

ITEM PART NO. DESCRIPTION QTY

1646884 Clutch Pack (Input/Forward-Low) ................................................................... 1
1 ..... Seal ................................................................................................................ 3
2 43207 Ball Bearing .................................................................................................. 3
3 1639865 Shaft ............................................................................................................... 1
3 4025480 Shaft (Alternate Part) ................................................................................... 1
4 ..... Seal ................................................................................................................ 1
5 ..... Seal ................................................................................................................ 1
6 2085129 Piston ............................................................................................................ 1
7 1581108 Spring ............................................................................................................ 1
8 1581098 Spring ............................................................................................................ 1
9 1581099 Spring Guide ................................................................................................. 1
10 1581100 Snap Ring ...................................................................................................... 1
11 ..... Conical Plate ................................................................................................. 1
12 ..... Friction Plate ................................................................................................. 9
13 ..... Separator Plate ............................................................................................. 8
14 1537449 Pressure Plate (6.0 mm) ............................................................................... 1
15 1537450 Snap Ring ...................................................................................................... 1
16 124603 Ball Bearing .................................................................................................. 1
17 1581107 Snap Ring ...................................................................................................... 1
18 ..... Seal ................................................................................................................ 1
19 1595428 Gear ............................................................................................................... 1
20 1537459 Snap Ring ...................................................................................................... 1
1652269 Kit-Clutch Pack Plates/Seals (Includes Items 1, 4-5, 11-13, 18) ........................ 1
1651852 Kit-Clutch Pack Plates (Includes Items 11-13) ............................................... 1
1595425 Kit-Clutch Pack Seals (Includes Items 1, 4-5, 18) .......................................... 1

©2011 HYSTER COMPANY See Service Manual 5-43

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

REVERSE CLUTCH (FIGURE 5-19)

SINGLE SPEED TRANSMISSION (→ S/N G004V02079E)

5-44 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

REVERSE CLUTCH
SINGLE SPEED TRANSMISSION (→ S/N G004V02079E)

ITEM PART NO. DESCRIPTION QTY

1524373 Clutch Pack ......................................................................................................... 1
1 ..... Seal ................................................................................................................ 2
2 1581116 Ball Bearing .................................................................................................... 2
3 1581114 Shaft ............................................................................................................... 1
4 ..... Seal ................................................................................................................ 1
5 ..... Seal ................................................................................................................ 1
6 1552525 Piston ............................................................................................................. 1
7 1581108 Spring ............................................................................................................. 1
8 1581098 Spring ............................................................................................................. 1
9 1581099 Spring Guide .................................................................................................. 1
10 1581100 Snap Ring ....................................................................................................... 1
11 ..... Conical Plate .................................................................................................. 1
12 ..... Friction Plate .................................................................................................. 8
13 ..... Separator Plate .............................................................................................. 7
14 1543094 Pressure Plate (5.8 mm) ................................................................................ 1
14 1537449 Pressure Plate (6.0 mm) ................................................................................ 1
14 1543096 Pressure Plate (5.6 mm) ................................................................................ 1
14 1543097 Pressure Plate (5.4 mm) ................................................................................ 1
14 1543098 Pressure Plate (5.2 mm) ................................................................................ 1
15 ..... Seal ................................................................................................................ 1
16 1537450 Snap Ring ....................................................................................................... 1
17 124603 Ball Bearing .................................................................................................... 1
18 1581107 Snap Ring ....................................................................................................... 1
19 1581117 Spacer ............................................................................................................ 1
20 1581106 Snap Ring ....................................................................................................... 1
21 1581115 Clutch Gear .................................................................................................... 1
21 1595427 Gear ............................................................................................................... 1
22 43207 Ball Bearing .................................................................................................... 1
1595426 Kit-Clutch Pack Plates/Seals (Includes Items 1, 4-5, 11-13, 15) ........................ 1
1543102 Kit-Clutch Pack Plates (Includes Items 11-13) ................................................... 1
1595425 Kit-Clutch Pack Seals (Includes Items 1, 4-5, 15) .............................................. 1

©2011 HYSTER COMPANY See Service Manual 5-45

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

REVERSE CLUTCH (FIGURE 5-20)

SINGLE SPEED TRANSMISSION (S/N G004V02080E →)

5-46 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

REVERSE CLUTCH
SINGLE SPEED TRANSMISSION (S/N G004V02080E →)

ITEM PART NO. DESCRIPTION QTY

1646888 Clutch Pack ......................................................................................................... 1
1 ..... Seal ................................................................................................................ 2
2 43207 Ball Bearing .................................................................................................... 3
3 1651762 Shaft ............................................................................................................... 1
3 4025493 Shaft (Alternate Part) ...................................................................................... 1
4 ..... Seal ................................................................................................................ 1
5 ..... Seal ................................................................................................................ 1
6 2085129 Piston ............................................................................................................. 1
7 1581108 Spring ............................................................................................................. 1
8 1581098 Spring ............................................................................................................. 1
9 1581099 Spring Guide .................................................................................................. 1
10 1581100 Snap Ring ....................................................................................................... 1
11 ..... Conical Plate .................................................................................................. 1
12 ..... Friction Plate .................................................................................................. 5
13 ..... Separator Plate .............................................................................................. 4
14 1537449 Pressure Plate (6.0 mm) ................................................................................ 1
15 ..... O-Ring ............................................................................................................ 1
16 1537450 Snap Ring ....................................................................................................... 1
17 124603 Ball Bearing .................................................................................................... 1
18 1581107 Snap Ring ....................................................................................................... 1
19 1537459 Snap Ring ....................................................................................................... 1
20 1651761 Clutch Gear .................................................................................................... 1
1652272 Kit-Repair ............................................................................................................ 1
1571673 Kit-Clutch Pack Plates (Clutch Pack Plates) (Includes Items 11-13) .................. 1
1595425 Kit-Clutch Pack Seals (Includes Items 1, 4-5, 15) .............................................. 1

©2011 HYSTER COMPANY See Service Manual 5-47

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

REVERSE CLUTCH (FIGURE 5-21)

DUAL SPEED TRANSMISSION (→ S/N G004V02223E)

5-48 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

REVERSE CLUTCH
DUAL SPEED TRANSMISSION (→ S/N G004V02223E)

ITEM PART NO. DESCRIPTION QTY

1524356 Clutch Pack (Reverse) ........................................................................................ 1
1 ..... Seal ................................................................................................................ 3
2 43207 Ball Bearing .................................................................................................... 3
3 1639862 Shaft ............................................................................................................... 1
4 ..... Seal ................................................................................................................ 1
5 ..... Seal ................................................................................................................ 1
6 2085129 Piston ............................................................................................................. 1
7 1581108 Spring ............................................................................................................. 1
8 1581098 Spring ............................................................................................................. 1
9 1581099 Spring Guide .................................................................................................. 1
10 1581100 Snap Ring ....................................................................................................... 1
11 ..... Conical Plate .................................................................................................. 1
12 ..... Friction Plate .................................................................................................. 9
13 ..... Separator Plate .............................................................................................. 8
14 1537449 Pressure Plate (6.0 mm) ................................................................................ 1
15 ..... Seal ................................................................................................................ 1
16 1537450 Snap Ring ....................................................................................................... 1
17 124603 Ball Bearing .................................................................................................... 1
18 1581107 Snap Ring ....................................................................................................... 1
19 1581105 Spacer ............................................................................................................ 1
20 1581106 Snap Ring ....................................................................................................... 1
21 1639863 Gear ............................................................................................................... 1
1595426 Kit-Clutch Pack Plates/Seals (Includes Items 1, 4-5, 11-13, 15) ........................ 1
1543102 Kit-Clutch Pack Plates (Includes Items 11-13) ................................................... 1
1595425 Kit-Clutch Pack Seals (Includes Items 1, 4-5) .................................................... 1

©2011 HYSTER COMPANY See Service Manual 5-49

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

REVERSE CLUTCH (FIGURE 5-22)

DUAL SPEED TRANSMISSION (S/N G004V02224E →)

5-50 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

REVERSE CLUTCH
DUAL SPEED TRANSMISSION (S/N G004V02224E →)

ITEM PART NO. DESCRIPTION QTY

1646886 Clutch Pack (Reverse) ...................................................................................... 1
1 ..... Seal ................................................................................................................ 3
2 43207 Ball Bearing .................................................................................................. 3
3 1639862 Shaft ............................................................................................................... 1
3 4025491 Shaft (Alternate Part) ................................................................................... 1
4 ..... Seal ................................................................................................................ 1
5 ..... Seal ................................................................................................................ 1
6 2085129 Piston ............................................................................................................ 1
7 1581108 Spring ............................................................................................................ 1
8 1581098 Spring ............................................................................................................ 1
9 1581099 Spring Guide ................................................................................................. 1
10 1581100 Snap Ring ...................................................................................................... 1
11 ..... Conical Plate ................................................................................................. 1
12 ..... Friction Plate ................................................................................................. 9
13 ..... Separator Plate ............................................................................................. 8
14 1537449 Pressure Plate (6.0 mm) ............................................................................... 1
15 ..... Seal ................................................................................................................ 1
16 1537450 Snap Ring ...................................................................................................... 1
17 124603 Ball Bearing .................................................................................................. 1
18 1581107 Snap Ring ...................................................................................................... 1
19 1581106 Snap Ring ....................................................................................................... 1
20 1639863 Gear ............................................................................................................... 1
1652269 Kit-Clutch Pack Plates/Seals (Includes Items 1, 4-5, 11-13, 15) ........................ 1
1651852 Kit-Clutch Pack Plates (Includes Items 11-13) ............................................... 1
1595425 Kit-Clutch Pack Seals (Includes Items 1, 4-5) ................................................ 1

©2011 HYSTER COMPANY See Service Manual 5-51

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-23)

DUAL SPEED, THREE PIECE HOUSING — SHEET 1 OF 2 (→ S/N G004V02228E (WET BRAKE))
(→ S/N G004V02223E DRY BRAKE)

5-52 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
DUAL SPEED, THREE PIECE HOUSING – SHEET 1 OF 2 (→ S/N G004V02228E (WET BRAKE))
(→ S/N G004V02223E DRY BRAKE)

ITEM PART NO. DESCRIPTION QTY

a 1529897 Transmission Assy (Dual Speed) (Without Boost) .............................................. 1
c 1552849 Transmission Assy (Dual Speed) (With Boost) ................................................... 1
1 292509 Capscrew ....................................................................................................... 11
2 320157 Washer ........................................................................................................... 12
3 c 1613695 Hydraulic Control Valve (Low Pressure) (FFigure 5-29)............................... 1
3 a 1611835 Hydraulic Control Valve (High Pressure) (FFigure 5-29).............................. 1
4 1570360 Gasket (Control Valve) ................................................................................... 1
5 2070263 Pressure Transducer ...................................................................................... 3
6 233693 Fitting .............................................................................................................. 1
6 16485 O-Ring ........................................................................................................ 1
7 1624507 Housing (Transmission) ................................................................................. 1
8 235691 Fitting .............................................................................................................. 7
8 16484 O-Ring ........................................................................................................ 7
9 1547447 Oil Seal ........................................................................................................... 1
10 1529874 Yoke (Fixed) (27 Tooth) ................................................................................. 1
11 86229 Seal ................................................................................................................ 1
12 15135 Washer ........................................................................................................... 1
13 15158 Washer ........................................................................................................... 1
14 18595 Capscrew ....................................................................................................... 1
15 43209 Ball Bearing .................................................................................................... 2
16 1550571 Screen (Suction) ............................................................................................. 1
17 1550572 Spring (Suction Screen) ................................................................................. 1
18 1487067 Fitting .............................................................................................................. 1
18 16485 O-Ring ........................................................................................................ 1
18 252729 O-Ring ........................................................................................................ 1
19 1524356 Clutch Pack (Reverse) (FFigure 5-21).......................................................... 1
20 1524371 Clutch Pack (Forward-High) (FFigure 5-15).................................................. 1
21 1541232 Sensor (Output Speed, TOSS) ....................................................................... 1
22 292500 Capscrew ....................................................................................................... 2
23 292680 Washer ........................................................................................................... 2
24 1541231 Sensor (Input Speed, TISS) ........................................................................... 1
25 1565135 Gear (Output) ................................................................................................. 1
26 1359458 Capscrew ....................................................................................................... 16
27 388049
292682 Lockwasher .................................................................................................... 23
28 1550582 Gasket (Cover To Transmission Housing) ..................................................... 1
29 1550581 Housing (Front Cover) .................................................................................... 1
30 292516 Capscrew ....................................................................................................... 3
31 334560 Magnet ........................................................................................................... 1
32 44309 Ball Bearing (Charge Pump) .......................................................................... 1
33 1585750 Gear (Idler) ..................................................................................................... 1
34 44306 Ball Bearing .................................................................................................... 1
35 1516851 Spacer ............................................................................................................ 1
36 1525686 Nut .................................................................................................................. 1
37 213099 Snap Ring ....................................................................................................... 1
38 1624401 Dipstick ........................................................................................................... 1
39 1624405 Fitting .............................................................................................................. 1
40 16485 O-Ring ........................................................................................................ 1
40 216590 Fitting ......................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 5-53

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION
DUAL SPEED, THREE PIECE HOUSING – SHEET 1 OF 2 (→ S/N G004V02228E (WET BRAKE))
(→ S/N G004V02223E DRY BRAKE)

ITEM PART NO. DESCRIPTION QTY

41 1632741 Breather .......................................................................................................... 1
41 16486 O-Ring ........................................................................................................ 1
42 1624407 Fitting .............................................................................................................. 1
43 16486 O-Ring ........................................................................................................ 1
44 303100 Roll Pin ........................................................................................................... 4
45 1553270 Snubber .......................................................................................................... 2
46 1553475 O-Ring ............................................................................................................ 2
47 d 222444 Fitting .............................................................................................................. 1
47 16486 O-Ring ........................................................................................................ 1
47 e 233683 Fitting .............................................................................................................. 1
47 16487 O-Ring ........................................................................................................ 1
48 303150 Dowel ............................................................................................................. 4
49 1612918 Spring (System Regulator) ............................................................................. 1
50 1612916 Spool (System Regulator) .............................................................................. 1
51 1553403 O-Ring ............................................................................................................ 1
52 1380849 Edge Protector ............................................................................................... 2
52 4013363 Trim (Alternate Part) ....................................................................................... 2
53 1527879 Capscrew ....................................................................................................... 1
54 1569768 Shield ............................................................................................................. 1
b 1566457 Baffle .............................................................................................................. 1

FOOTNOTES:
a Dry Brake d → S/N G004V01515D
b Not Illustrated e S/N G004V01516D →
c Wet Brake

5-54 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 5-55

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-24)

DUAL SPEED, THREE PIECE HOUSING — SHEET 2 OF 2 (→ S/N G004V00228E (WET BRAKE))
(→ S/N G004V02223E DRY BRAKE)

5-56 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
DUAL SPEED, THREE PIECE HOUSING – SHEET 2 OF 2 (→ S/N G004V00228E (WET BRAKE))
(→ S/N G004V02223E DRY BRAKE)

ITEM PART NO. DESCRIPTION QTY

a 1529897 Transmission Assy (Dual Speed) (Without Boost) .............................................. 1
b 1552849 Transmission Assy (Dual Speed) (With Boost) ................................................... 1
1 1624504 Converter Housing (Torque Convertor) .......................................................... 1
2 1544217 Oil Seal (Torque Converter) ........................................................................... 1
3 44310 Ball Bearing .................................................................................................... 1
4 145481 O-Ring ............................................................................................................ 1
5 1541556 Sprocket ......................................................................................................... 1
6 1544216 Bearing ........................................................................................................... 1
7 1544218 Sealing Ring ................................................................................................... 1
8 136985 Capscrew ....................................................................................................... 4
9 1525677 Stator .............................................................................................................. 1
9 1516826 Bushing ...................................................................................................... 1
10 16682 O-Ring ............................................................................................................ 1
11 1524355 Clutch Pack (Input/Forward-Low) (FFigure 5-17).......................................... 1
12 1550573 Gasket (Torque Converter Housing to Cover) ................................................ 1
13 1515654 Temperature Sensor ...................................................................................... 1
14 292680 Washer ........................................................................................................... 2
15 292500 Capscrew ....................................................................................................... 2
16 1550567 Cover Plate (Torque Converter Housing) ....................................................... 1
17 188210 Fitting .............................................................................................................. 1
17 16983 O-Ring ........................................................................................................ 1
18 43209 Ball Bearing .................................................................................................... 1
19 1529890 Sprocket (Driven) ........................................................................................... 1
20 1494750 Chain (Drive Pump) ........................................................................................ 1
21 44307 Ball Bearing .................................................................................................... 1
22 1653815 Gasket (Charge Pump) .................................................................................. 1
23 c 2073470 Pump (32.4 CC/REV Without Boost) .............................................................. 1
23 b 2076527 Pump (32.4 CC/REV With Boost) ................................................................... 1
23 1623836 O-Ring ........................................................................................................ 1
24 292681 Lockwasher .................................................................................................... 6
25 296022 Capscrew ....................................................................................................... 4
26 1566169 Cover .............................................................................................................. 1
27 2075558 Transmission Filter ......................................................................................... 1
28 1558515 Fitting .............................................................................................................. 1
29 292526 Capscrew ....................................................................................................... 1
30 292683 Lockwasher .................................................................................................... 1
31 320161 Washer ........................................................................................................... 1

FOOTNOTES:
a Dry Brake c Wet or Dry Brake
b Wet Brake

©2011 HYSTER COMPANY See Service Manual 5-57

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-25)

DUAL SPEED, THREE PIECE HOUSING, SHEET 1 OF 2
(S/N G004V02224E ↔ S/N G004V02842E DRY BRAKE)
(S/N G004V02229E ↔ S/N G004V02846E WET BRAKE)

5-58 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
DUAL SPEED, THREE PIECE HOUSING, SHEET 1 OF 2 (S/N G004V02224E ↔ S/N G004V02842E DRY BRAKE)
(S/N G004V02229E ↔ S/N G004V02846E WET BRAKE)

ITEM PART NO. DESCRIPTION QTY

a 1646875 Transmission Assy (Dual Speed without Boost) ................................................. 2
c 1646876 Transmission Assy (Dual Speed with Boost) ...................................................... 1
1 292509 Capscrew ...................................................................................................... 11
2 320157 Washer .......................................................................................................... 12
3 c 1613695 Hydraulic Control Valve (Low Pressure) (FFigure 5-29)............................... 1
3 a 1611835 Hydraulic Control Valve (High Pressure) (FFigure 5-29).............................. 1
4 1570360 Gasket (Control Valve) ................................................................................. 1
5 2070263 Pressure Transducer ................................................................................... 1
6 233693 Fitting ............................................................................................................ 1
6 16485 O-Ring ....................................................................................................... 1
7 1639068 Transmission Housing .................................................................................... 1
8 235691 Fitting ............................................................................................................ 6
8 16484 O-Ring ....................................................................................................... 6
9 1547447 Oil Seal .......................................................................................................... 1
10 1529874 Yoke (Fixed) (27 Tooth) ................................................................................. 1
11 86229 Seal ................................................................................................................ 1
12 15135 Washer ........................................................................................................... 1
13 15158 Washer ........................................................................................................... 1
14 18595 Capscrew ....................................................................................................... 1
15 43209 Ball Bearing .................................................................................................. 2
16 1550571 Screen (Suction) ............................................................................................. 1
17 1550572 Spring (Suction Screen) .............................................................................. 1
18 1545546 Fitting ............................................................................................................ 2
18 16481 O-Ring ....................................................................................................... 1
19 1646886 Clutch Pack (Reverse) (FFigure 5-16)....................................................... 1
20 1646885 Clutch Pack (Forward-High) (FFigure 5-16).............................................. 1
21 1541232 Sensor (Output Speed, TOSS) .................................................................... 1
22 292500 Capscrew ...................................................................................................... 2
23 292680 Washer .......................................................................................................... 2
24 1541231 Sensor (Input Speed, TISS) ......................................................................... 1
25 1565135 Gear (Output) ................................................................................................. 1
26 1359458 Capscrew ....................................................................................................... 16
27 388049
292682 Lockwasher ................................................................................................... 23
28 1550582 Gasket (Cover To Transmission Housing) ..................................................... 1
29 1550581 Housing (Front Cover) .................................................................................... 1
30 292516 Capscrew ...................................................................................................... 3
31 334560 Magnet ........................................................................................................... 1
32 44309 Ball Bearing (Charge Pump) ........................................................................ 1
33 1585750 Gear (Idler) .................................................................................................... 1
34 44306 Ball Bearing .................................................................................................. 1
35 1516851 Spacer ............................................................................................................ 1
36 1525686 Nut ................................................................................................................. 1
37 213099 Snap Ring ...................................................................................................... 1
38 1624401 Dipstick ......................................................................................................... 1
39 1624405 Fitting .............................................................................................................. 1
40 16485 O-Ring ....................................................................................................... 1
41 1632741 Breather ......................................................................................................... 1
41 16486 O-Ring ....................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 5-59

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION
DUAL SPEED, THREE PIECE HOUSING, SHEET 1 OF 2 (S/N G004V02224E ↔ S/N G004V02842E DRY BRAKE)
(S/N G004V02229E ↔ S/N G004V02846E WET BRAKE)

ITEM PART NO. DESCRIPTION QTY

42 1486555 Fitting .............................................................................................................. 1
42 16485 O-Ring ....................................................................................................... 1
43 252729 O-Ring ....................................................................................................... 1
44 303100 Roll Pin .......................................................................................................... 4
45 1553270 Snubber .......................................................................................................... 2
46 1553475 O-Ring ............................................................................................................ 2
47 233683 Fitting ............................................................................................................ 1
47 16487 O-Ring ....................................................................................................... 1
48 303150 Dowel ............................................................................................................. 4
49 1612918 Spring (System Regulator) .......................................................................... 1
50 1612916 Spool (System Regulator) ........................................................................... 1
51 1553403 O-Ring ........................................................................................................... 1
52 d 1530722 Solenoid Valve ............................................................................................... 1
52 1650819 Kit-Seal ...................................................................................................... 1
52 e 1660500 Solenoid Valve .............................................................................................. 1
52 1650819 Kit-Seal ...................................................................................................... 1
53 293742 Screw ............................................................................................................. 2
54 1569768 Shield ............................................................................................................. 1
55 1380849 Edge Protector .............................................................................................. 2
55 4013363 Trim (Alternate Part) ....................................................................................... 2
56 1527879 Capscrew ...................................................................................................... 1
b 1624414 Baffle .............................................................................................................. 1
b 1624415 Cover (Pump Drive) ........................................................................................ 1

FOOTNOTES:
a Dry Brake d → PENDING PER ECN 104793
b Not Illustrated e PENDING PER ECN 104793 →
c Wet Brake

5-60 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION (FIGURE 5-26)

DUAL SPEED, THREE PIECE HOUSING, SHEET 2 OF 2
(S/N G004V02224E ↔ S/N G004V02842E DRY BRAKE)
(S/N G004V02229E ↔ S/N G004V02846E WET BRAKE)

ITEM PART NO. DESCRIPTION QTY

a 1646875 Transmission Assy (Dual Speed without Boost) ................................................. 1
b 1646876 Transmission Assy (Dual Speed with Boost) ...................................................... 1
1 1624504 Converter Housing ......................................................................................... 1
2 1544217 Oil Seal (Torque Converter) ........................................................................... 1
3 44310 Ball Bearing .................................................................................................... 1
4 145481 O-Ring ............................................................................................................ 1
5 1541556 Sprocket (Driving) ........................................................................................... 1
6 1544216 Bearing ........................................................................................................... 1
7 1544218 Sealing Ring ................................................................................................... 1
8 136985 Capscrew ....................................................................................................... 4
9 1525677 Stator .............................................................................................................. 1
9 1516826 Bushing ...................................................................................................... 1
10 16682 O-Ring ............................................................................................................ 1
11 1646884 Clutch Pack (Input/Forward-Low) (FFigure 5-18).......................................... 1
12 1550573 Gasket (Torque Converter Housing to Cover) ................................................ 1
13 1515654 Temperature Sensor ...................................................................................... 1
14 292680 Washer ........................................................................................................... 2
15 292500 Capscrew ....................................................................................................... 2
16 1550567 Cover Plate (Torque Converter Housing) ....................................................... 1
17 188210 Fitting .............................................................................................................. 1
17 16983 O-Ring ........................................................................................................ 1
18 43209 Ball Bearing .................................................................................................... 1
©2011 HYSTER COMPANY See Service Manual 5-61
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ITEM PART NO. DESCRIPTION QTY

19 1529890 Sprocket (Driven) ........................................................................................... 1
20 1494750 Chain (Drive Pump) ........................................................................................ 1
21 44307 Ball Bearing .................................................................................................... 1
22 1653815 Gasket (Charge Pump) .................................................................................. 1
23 a 2073470 Pump (32.4 CC/REV Without Boost) .............................................................. 1
23 b 2076527 Pump (32.4 CC/REV With Boost) ................................................................... 1
23 1623836 O-Ring ........................................................................................................ 1
24 292681 Lockwasher .................................................................................................... 6
25 296022 Capscrew ....................................................................................................... 4
26 1566169 Cover .............................................................................................................. 1
27 2075558 Transmission Filter ......................................................................................... 1
28 1558515 Fitting .............................................................................................................. 1
29 292526 Capscrew ....................................................................................................... 1
30 292683 Lockwasher .................................................................................................... 1
31 320161 Washer ........................................................................................................... 1

FOOTNOTES:
a Dry Brake b Wet Brake

5-62 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 5-63

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-27)

DUAL SPEED, TWO PIECE HOUSING — SHEET 1 OF 2 (S/N G004V02843E → (DRY BRAKE))
(S/N G004V02847E → (WET BRAKE))

5-64 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
DUAL SPEED, TWO PIECE HOUSING – SHEET 1 OF 2 (S/N G004V02843E → (DRY BRAKE))
(S/N G004V02847E → (WET BRAKE))

ITEM PART NO. DESCRIPTION QTY

a 1636633 Transmission Assy (Dual Speed Dry Brake) ...................................................... 1
c 1703474 Transmission Assy (Dual Speed Dry Brake) ...................................................... 1
a 1636634 Transmission Assy (Dual Speed Wet Brake) ...................................................... 1
c 1703475 Transmission Assy (Dual Speed Wet Brake) ................................................. 1
1 1636639 Converter Housing (Torque Converter) ..................................................... 1
2 1632741 Breather ......................................................................................................... 1
2 16486 O-Ring ....................................................................................................... 1
3 1624406 Dipstick Tube ................................................................................................ 1
4 1624401 Dipstick ......................................................................................................... 1
5 1622888 Cover (Converter Housing) ............................................................................ 1
5 1699141 Cover Plate (Converter Housing) (Alternate Part) ..................................... 1
6 292681 Lockwasher ................................................................................................... 6
7 2075558 Transmission Filter ......................................................................................... 1
7 4020588 Transmission Filter (Alternate Part) ................................................................ 1
8 1558515 Fitting ............................................................................................................ 1
9 136681 Capscrew ...................................................................................................... 2
10 1640573 Fitting ............................................................................................................ 1
11 235691 Fitting ............................................................................................................ 4
11 16484 O-Ring ....................................................................................................... 1
12 1624408 Shield (Upper) ............................................................................................... 1
13 292680 Washer .......................................................................................................... 1
14 148962 Capscrew ...................................................................................................... 1
15 1525677 Stator ............................................................................................................. 1
15 1516826 Bushing ..................................................................................................... 1
16 16682 O-Ring ........................................................................................................... 1
17 145481 O-Ring ........................................................................................................... 1
18 1544217 Oil Seal (Torque Converter) ......................................................................... 1
19 1541556 Sprocket ........................................................................................................ 1
20 1544216 Bearing .......................................................................................................... 1
21 1494750 Chain (Drive Pump) ...................................................................................... 1
22 1615804 Snubber ......................................................................................................... 2
23 303100 Roll Pin .......................................................................................................... 4
24 296022 Capscrew ...................................................................................................... 4
25 1653815 Gasket ........................................................................................................... 1
26 1553403 O-Ring ........................................................................................................... 4
27 2070263 Pressure Transducer ................................................................................... 2
28 1612918 Spring ............................................................................................................ 1
29 1612916 Spool ............................................................................................................. 1
30 222443 Fitting ............................................................................................................ 1
30 16485 O-Ring ....................................................................................................... 1
31 233693 Fitting ............................................................................................................ 2
31 16485 O-Ring ....................................................................................................... 1
32 1636626 Carrier ............................................................................................................ 1
33 292516 Capscrew ...................................................................................................... 7
34 388049
292682 Lockwasher ................................................................................................... 7
35 136985 Capscrew ...................................................................................................... 4
36 43209 Ball Bearing .................................................................................................. 1
37 44307 Ball Bearing .................................................................................................. 1

©2011 HYSTER COMPANY See Service Manual 5-65

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION
DUAL SPEED, TWO PIECE HOUSING – SHEET 1 OF 2 (S/N G004V02843E → (DRY BRAKE))
(S/N G004V02847E → (WET BRAKE))

ITEM PART NO. DESCRIPTION QTY

38 1544218 Sealing Ring .................................................................................................. 1
39 44310 Ball Bearing .................................................................................................. 1
40 b 1487067 Fitting .............................................................................................................. 1
40 252729 O-Ring ....................................................................................................... 1
40 16485 O-Ring ....................................................................................................... 1
41 2076527 Pump (Charge) .............................................................................................. 1

FOOTNOTES:
a → S/N G004V04081F c S/N G004V04082F →
b PENDING PER ECN 10481702 →

5-66 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 5-67

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION (FIGURE 5-28)

DUAL SPEED, TWO PIECE HOUSING — SHEET 2 OF 2 (S/N G004V02843E → (DRY BRAKE))
(S/N G004V02847E → (WET BRAKE))

5-68 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION
DUAL SPEED, TWO PIECE HOUSING – SHEET 2 OF 2 (S/N G004V02843E → (DRY BRAKE))
(S/N G004V02847E → (WET BRAKE))

ITEM PART NO. DESCRIPTION QTY

a 1636633 Transmission Assy (Dual Speed Dry Brake) (Without Boost) ............................. 1
b 1703474 Transmission Assy (Dual Speed Dry Brake) ...................................................... 1
a 1636634 Transmission Assy (Dual Speed Wet Brake) (With Boost) ................................. 1
b 1703475 Transmission Assy (Dual Speed Wet Brake) ................................................. 1
1 1622887 Baffle ............................................................................................................. 1
2 292500 Capscrew ...................................................................................................... 4
3 292680 Washer .......................................................................................................... 7
4 303150 Dowel ............................................................................................................. 4
5 334560 Magnet ........................................................................................................... 1
6 1550567 Cover Plate .................................................................................................... 1
7 213099 Snap Ring ...................................................................................................... 1
8 44309 Ball Bearing .................................................................................................. 1
9 1525686 Nut ................................................................................................................. 1
10 1636645 Spacer ........................................................................................................... 1
11 43209 Ball Bearing .................................................................................................. 2
12 1585750 Gear (Idler) .................................................................................................... 1
13 44306 Ball Bearing .................................................................................................. 1
14 1636640 Gasket ........................................................................................................... 1
15 235691 Fitting ............................................................................................................ 4
15 16484 O-Ring ....................................................................................................... 1
16 292522 Capscrew ...................................................................................................... 2
17 388049
292682 Lockwasher ................................................................................................... 21
18 1541232 Sensor (Output Speed, TOSS) .................................................................... 1
19 1541231 Sensor (Input Speed, TISS) ......................................................................... 1
20 320157 Washer .......................................................................................................... 11
21 235691 Fitting ............................................................................................................ 4
21 16484 O-Ring ....................................................................................................... 1
22 1570360 Gasket ........................................................................................................... 1
23 292509 Capscrew ...................................................................................................... 11
24 1652575 Bracket .......................................................................................................... 1
25 292515 Capscrew ...................................................................................................... 15
26 293742 Screw ............................................................................................................. 2
27 1660500 Solenoid Valve .............................................................................................. 1
28 1636630 Transmission Housing ................................................................................. 1
29 222444 Fitting ............................................................................................................ 1
29 16486 O-Ring ....................................................................................................... 1
30 1654651 Flange Head Capscrew ................................................................................ 1
31 1547447 Oil Seal .......................................................................................................... 1
32 1515654 Temperature Sensor .................................................................................... 1
33 86229 Seal ................................................................................................................ 1
34 1638793 Gear (Output) ................................................................................................ 1
35 148962 Capscrew ...................................................................................................... 3
36 1627453 Shield (Lower) ............................................................................................... 1
37 1627465 Screen ........................................................................................................... 1
38 1550572 Spring ............................................................................................................ 1
39 188210 Fitting ............................................................................................................ 1
39 16983 O-Ring ....................................................................................................... 1
40 1545546 Fitting ............................................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 5-69

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION
DUAL SPEED, TWO PIECE HOUSING – SHEET 2 OF 2 (S/N G004V02843E → (DRY BRAKE))
(S/N G004V02847E → (WET BRAKE))

ITEM PART NO. DESCRIPTION QTY

41 2070263 Pressure Transducer ................................................................................... 1
42 1654004 Yoke ............................................................................................................... 1

FOOTNOTES:
a → S/N G004V04081F b S/N G004V04082F →

5-70 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 5-71

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION CONTROL VALVE ASSEMBLY (FIGURE 5-29)

(→ PENDING PER ECN 104793)

5-72 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TRANSMISSION CONTROL VALVE ASSEMBLY

(→ PENDING PER ECN 104793)

ITEM PART NO. DESCRIPTION QTY

b 1613695 Hydraulic Control Valve ...................................................................................... 1
a 1611835 Hydraulic Control Valve ...................................................................................... 1
1 ..... Body ............................................................................................................... 1
2 2070263 Pressure Transducer ...................................................................................... 2
3 1545546 Fitting .............................................................................................................. 2
3 16481 O-Ring ........................................................................................................ 2
4 1530722 Solenoid Valve ............................................................................................... 2
4 1650819 Kit-Seal ....................................................................................................... 1
5 293742 Screw ............................................................................................................. 6
6 1590866 Return Spring ................................................................................................. 1
7 1590865 Spool (Cut-Off) ............................................................................................... 1
8 1590839 Spool (Stop) ................................................................................................... 1
9 233693 Fitting .............................................................................................................. 3
9 16485 O-Ring ........................................................................................................ 3
10 1520660 Solenoid ......................................................................................................... 1
11 1613470 Spool (Torque Converter Regulator) .............................................................. 1
12 1550561 Spring (Proportional Control Regulator) ......................................................... 1
13 1544759 Spool (Torque Converter Regulator) .............................................................. 1
14 1514138 Spring (Torque Converter Regulator) ............................................................. 1

FOOTNOTES:
a Single and Dual Speed Transmission with Dry b Single and Dual Speed Transmission with Wet
Brake Brake

©2011 HYSTER COMPANY See Service Manual 5-73

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TRANSMISSION CONTROL VALVE ASSEMBLY (FIGURE 5-30)

(PENDING PER ECN 104793 →)

ITEM PART NO. DESCRIPTION QTY

1665204 Valve (High Pressure) (Dry Brake) ..................................................................... 1
1665205 Valve (Low Pressure) (Wet Brake) .................................................................. 1
1 ..... Body .............................................................................................................. 1
2 233693 Fitting ............................................................................................................ 3
3 1550561 Spring ............................................................................................................ 1
4 1613470 Spool (High Pressure) .................................................................................... 1
4 1610746 Spool (Low Pressure) .................................................................................. 1
5 1514138 Spring ............................................................................................................ 1
6 1544759 Spool ............................................................................................................. 1
7 1660500 Solenoid Valve .............................................................................................. 2
7 1650819 Kit-Seal ...................................................................................................... 1
8 293741 Capscrew ...................................................................................................... 6
9 1520660 Solenoid ........................................................................................................ 1
10 1590865 Spool (Cut-Off) .............................................................................................. 1
11 1590866 Return Spring ............................................................................................... 1
12 1545546 Fitting ............................................................................................................ 2
13 1590839 Spool (Stop) .................................................................................................. 1

5-74 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

6 DRIVE AXLE
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 6
DRIVE AXLE

DESCRIPTION PAGE

CARRIER ASSEMBLY
DRY BRAKE ................................................................................................................................................ 6-20
DIFFERENTIAL
DRY BRAKE ................................................................................................................................................ 6-14
WET BRAKE ............................................................................................................................................... 6-16
DRIVE AXLE
DRY BRAKE ................................................................................................................................................ 6-2
DRIVE AXLE AND ATTACHING PARTS
WET BRAKE (→ S/N G004V01514D) ....................................................................................................... 6-6
WET BRAKE (S/N G004V01515D →) ....................................................................................................... 6-8
DRIVE AXLE HOUSING AND HUB
WET BRAKE ............................................................................................................................................... 6-10
DRIVE TIRE AND WHEEL .............................................................................................................................. 6-24
WET BRAKES ................................................................................................................................................. 6-22

©2011 HYSTER COMPANY See Service Manual 6-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DRIVE AXLE (FIGURE 6-1)

DRY BRAKE

6-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

DRIVE AXLE
DRY BRAKE

ITEM PART NO. DESCRIPTION QTY

c 1542094 Drive Axle (0.79 Gear Ratio Gasoline and LPG) ................................................ 1
b 1542097 Drive Axle (0.89 Gear Ratio Diesel) .................................................................... 1
c 1542095 Drive Axle (0.89 Gear Ratio Diesel) .................................................................... 1
b 1542096 Drive Axle (0.79 Gear Ratio Gasoline and LPG) ................................................ 1
1 c 2088389 Tube Assy (RH) .............................................................................................. 1
1 b 2088391 Tube Assy (RH) .............................................................................................. 1
2 1608822 Manifold Assy ................................................................................................. 1
2 ..... Bracket ....................................................................................................... 1
2 1595808 Manifold ...................................................................................................... 1
3 1510126 Screw (Button Head) .................................................................................. 2
4 292680 Washer ....................................................................................................... 2
5 1542160 Housing (Differential) ...................................................................................... 1
6 1375487 Bearing Set ..................................................................................................... 2
7 1652926 Retainer .......................................................................................................... 2
8 2029436 Bolt ................................................................................................................. 12
9 2083424
2098414 Gear Set ......................................................................................................... 1
10 1556795 Gear ............................................................................................................... 2
11 2067574 Differential (Assembly) (FFigure 6-5)............................................................ 1
11 ..... Case Set .................................................................................................... 1
11 2029383 Spider (Assembly) ...................................................................................... 1
11 1565324 Kit-Washer (Kit) .......................................................................................... 1
11 1565327 Bolt ............................................................................................................. 8
11 1606531 Kit-Gear ...................................................................................................... 1
11 ..... Side Gear ................................................................................................... 2
11 ..... Pinion ......................................................................................................... 4
12 15241 Cotter Pin ....................................................................................................... 2
12 302449 Roll Pin ........................................................................................................... 2
13 14604 Plug ................................................................................................................ 1
13 16487 O-Ring ........................................................................................................ 1
14 17735 Fitting .............................................................................................................. 1
15 21420 Breather .......................................................................................................... 1
16 1542161 Support ........................................................................................................... 1
17 293692 Capscrew ....................................................................................................... 4
18 296426 Washer ........................................................................................................... 4
19 234038 Dowel ............................................................................................................. 4
20 292683 Lockwasher .................................................................................................... 12
21 292528 Capscrew ....................................................................................................... 11
22 292526 Capscrew ....................................................................................................... 1
23 1542143 Ball Bearing .................................................................................................... 2
24 c 1664495 Drive Gear ...................................................................................................... 1
24 bd 1542103 Drive Gear ...................................................................................................... 1
24 bf 1664496 Gear (Drive) (Alternate Part) .......................................................................... 1
25 1542144 Transmission Housing .................................................................................... 1
26 e 292681 Lockwasher .................................................................................................... 19
26 g 292681 Lockwasher .................................................................................................... 18
27 292508 Capscrew ....................................................................................................... 10
28 1542169 Oil Seal ........................................................................................................... 1
29 1542146 Shaft (Input) .................................................................................................... 1
30 1594314 Universal Joint ................................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 6-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DRIVE AXLE
DRY BRAKE

ITEM PART NO. DESCRIPTION QTY

31 287851 Capscrew ....................................................................................................... 5
32 c 1516536 Cover .............................................................................................................. 1
32 b 1542147 Dust Cover ..................................................................................................... 1
33 e 2026861 Nut .................................................................................................................. 1
34 1530588 Washer ........................................................................................................... 1
35 2022352 Tapered Roller Bearing .................................................................................. 1
36 1516331 Shim (0.004 in.) .............................................................................................. AR
36 1516332 Shim (0.005 in.) .............................................................................................. AR
36 1516333 Shim (0.007 in.) .............................................................................................. AR
36 1516334 Shim (0.009 in.) .............................................................................................. AR
36 1516335 Shim (0.19 in.) ................................................................................................ AR
37 1664499 Gear (Gasoline and LPG) ............................................................................... 1
37 d 1542105 Gear (Diesel) .................................................................................................. 1
37 f 1664500 Gear (Alternate Part) ...................................................................................... 1
38 153070 Clamp ............................................................................................................. 2
38 175821 Clamp (Alternate Part) .................................................................................... 1
39 2028862 Tapered Roller Bearing .................................................................................. 1
40 1520752 Shim (0.012 in.) .............................................................................................. AR
40 1520753 Shim (0.016 in.) .............................................................................................. AR
40 1520754 Shim (0.19 in.) ................................................................................................ AR
40 1520755 Shim (0.04 in.) ................................................................................................ AR
40 1569912 Shim (0.008 in.) .............................................................................................. AR
40 1569913 Shim (0.009 in.) .............................................................................................. AR
40 1569914 Shim (0.014 in.) .............................................................................................. AR
40 1569915 Shim (0.018 in.) .............................................................................................. AR
41 234038 Dowel (Pin) ..................................................................................................... 4
41 302385 Dowel (Pin) ..................................................................................................... 7
42 1601968 Carrier (FFigure 6-7)..................................................................................... 2
43 1521809 Drain Plug ....................................................................................................... 1
43 16983 O-Ring ........................................................................................................ 1
44 1556794 Gear (Internal) ................................................................................................ 2
45 1542157 Washer ........................................................................................................... 2
46 2083429 Lockwasher .................................................................................................... 2
47 2039504 Nut .................................................................................................................. 2
48 c 1542133 Axle Shaft ....................................................................................................... 2
48 b 1542134 Axle Shaft ....................................................................................................... 2
49 293646 Capscrew ....................................................................................................... 24
50 c 1542124 Hub ................................................................................................................. 2
50 b 1542125 Hub ................................................................................................................. 2
51 c 1542170 Hub ............................................................................................................. 1
51 b 1542171 Hub ............................................................................................................. 1
52 1542138 Wheel Stud ................................................................................................. 8
53 2039494 Bearing Set ................................................................................................ 1
54 2039492 Seal ............................................................................................................ 1
55 1375498 Bearing Set ................................................................................................ 1
56 302385 Dowel (Pin) ................................................................................................. 2
57 1615652 Bolt (Serrated) ................................................................................................ 16
58 296426 Washer ........................................................................................................... 20
59 c 1633017
1641955 Brake Assembly (LH) (FFigure 8-1).............................................................. 1

6-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

DRIVE AXLE
DRY BRAKE

ITEM PART NO. DESCRIPTION QTY

1688564
59 b 1633124
1641953
1688551 Brake Assy (LH) (FFigure 8-2)...................................................................... 1
59 c 1633018
1641956
1688565 Brake and Cable Assy (RH) (FFigure 8-1).................................................... 1
59 b 1633125
1641954
1688552 Brake Assembly (RH) (FFigure 8-2).............................................................. 1
60 c 1608395 Hanger (LH) .................................................................................................... 1
60 b 1608396 Hanger (LH) .................................................................................................... 1
60 c 1608397 Hanger (RH) ................................................................................................... 1
60 b 1608398 Hanger (RH) ................................................................................................... 1
61 1608403 Seal ............................................................................................................ 1
62 302385 Dowel (Pin) ................................................................................................. 2
63 293695 Capscrew ....................................................................................................... 20
64 226430 Capscrew ....................................................................................................... 4
65 296434 Washer ........................................................................................................... 4
66 c 2088388 Tube Assy (LH) .............................................................................................. 1
66 b 2088390 Tube Assy (LH) .............................................................................................. 1
67 g 320157 Washer ........................................................................................................... 1
68 e 292681 Lockwasher .................................................................................................... 1
69 2088151 Bracket (Wire Guard) ..................................................................................... 2
70 136681 Capscrew ....................................................................................................... 4
71 1329286 Capscrew ....................................................................................................... 8
75 a 1673612 Identification Plate .......................................................................................... 1
75 a 1705402 Identification Plate (Alternate Part) ................................................................. 1
a 376026 Wheel Nut ....................................................................................................... 16

FOOTNOTES:
a Not Illustrated e → S/N G004V01515D
b S100-120FT f 12/2007 →
c S80FT, S100BCS g S/N G004V01516D →
d → 12/2007

©2011 HYSTER COMPANY See Service Manual 6-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DRIVE AXLE AND ATTACHING PARTS (FIGURE 6-2)

WET BRAKE (→ S/N G004V01514D)

6-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

DRIVE AXLE AND ATTACHING PARTS

WET BRAKE (→ S/N G004V01514D)

ITEM PART NO. DESCRIPTION QTY

1 f 2063158 Drive Axle (11.2 Overall Ratio) ........................................................................... 1
1 de 2063159 Drive Axle (12.8 Overall Ratio) ........................................................................... 1
1 c 2063843 Drive Axle (11.2 Overall Ratio) ........................................................................... 1
1 ab 2063844 Drive Axle (12.8 Overall Ratio) ........................................................................... 1
2 296434 Washer ............................................................................................................... 4
3 226430 Capscrew ............................................................................................................ 4
4 1594314 Universal Joint .................................................................................................... 1
5 1329286 Capscrew ............................................................................................................ 8
6 def 1623891 Guard (Left) ........................................................................................................ 1
6 abc 1623893 Guard (Left) ........................................................................................................ 1
7 def 1623892 Guard (Right) ...................................................................................................... 1
7 abc 1623894 Guard (Right) ...................................................................................................... 1
8 1527880 Capscrew ............................................................................................................ 2
9 1627171 Bracket ................................................................................................................ 1
10 1527883 Capscrew ............................................................................................................ 2
11 1530243 Insert ................................................................................................................... 2
12 1626353 Bracket ................................................................................................................ 1
13 1510113 Capscrew ............................................................................................................ 2
14 376026 Wheel Nut ........................................................................................................... 16

FOOTNOTES:
a S100-120FT Diesel d S80 FT Diesel
b S100-120FT With Extended Function Dual Speed e S80FT With Extended Function Dual Speed
Transmission Transmission
c S100-120FT Without Extended Function Dual f S80FT Without Extended Function Dual Speed
Speed Transmission Transmission

©2011 HYSTER COMPANY See Service Manual 6-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DRIVE AXLE AND ATTACHING PARTS (FIGURE 6-3)

WET BRAKE (S/N G004V01515D →)

6-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

DRIVE AXLE AND ATTACHING PARTS

WET BRAKE (S/N G004V01515D →)
KEY:
A: S80FT
B: S100-120FT
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 bd 2090890 Drive Axle (11.2 Overall Ratio) ................................................................... 1 ..
1 abc 2090891 Drive Axle (12.8 Overall Ratio) ................................................................... 1 ..
1 bd 2090896 Drive Axle (11.2 Overall Ratio) ................................................................ .. 1
1 abc 2090897 Drive Axle (12.8 Overall Ratio) ................................................................... .. 1
2 296434 Washer ...................................................................................................... 4 4
3 226430 Capscrew .................................................................................................. 4 4
4 1594314 Universal Joint ......................................................................................... 1 1
5 1329286 Capscrew .................................................................................................. 8 8
6 1623891 Guard (Left Hand) ..................................................................................... 1 ..
6 1623893 Guard (Left Hand) ...................................................................................... .. 1
6 1623891 Guard (Left Hand) (Alternate Part) .......................................................... .. 1
7 1623892 Guard (Right Hand) .................................................................................. 1 ..
7 1623894 Guard (Right Hand) .................................................................................... .. 1
7 1623892 Guard (Right Hand) (Alternate Part) ....................................................... .. 1
8 1527880 Capscrew .................................................................................................. 2 2
9 1626353 Bracket ...................................................................................................... 1 1
10 1510113 Capscrew .................................................................................................. 2 2
11 376026 Wheel Nut .................................................................................................. 16 16

FOOTNOTES:
a Diesel with Any Transmission c With Extended Function Dual Speed Transmission
b Gasoline and LPG d Without Extended Function Dual Speed
Transmission

©2011 HYSTER COMPANY See Service Manual 6-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DRIVE AXLE HOUSING AND HUB (FIGURE 6-4)

WET BRAKE

6-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

DRIVE AXLE HOUSING AND HUB

WET BRAKE
KEY:
A: S80FT
B: S100-120FT
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
cd 2063158 Drive Axle (11.2 Overall Ratio) ................................................................... 1 ..
ce 2090890 Drive Axle (11.2 Overall Ratio) ................................................................... 1 ..
abd 2063159 Drive Axle (12.8 Overall Ratio) ................................................................... 1 ..
abe 2090891 Drive Axle (12.8 Overall Ratio) ................................................................... 1 ..
cd 2063843 Drive Axle (11.2 Overall Ratio) ................................................................... .. 1
ce 2090896 Drive Axle (11.2 Overall Ratio) ................................................................ .. 1
abd 2063844 Drive Axle (12.8 Overall Ratio) ................................................................... .. 1
bae 2090897 Drive Axle (12.8 Overall Ratio) ................................................................... .. 1
1 ..... Axle Housing (RH) .................................................................................... 1 1
2 1623668 Tube (Long) ........................................................................................... 1 ..
2 1623826 Tube (long) ........................................................................................... .. 1
3 1623654 O-Ring ................................................................................................... 1 1
4 1623658 Bolt ........................................................................................................ 4 4
5 d 1623665 Support .................................................................................................. 1 1
5 e 1627817 Support ................................................................................................. 1 1
6 1623666 Bolt ........................................................................................................ 4 4
7 ..... Axle Housing (LH) ................................................................................ 1 1
8 1623667 Tube (Short) ........................................................................................... 1 ..
8 1623825 Tube (Short) ......................................................................................... .. 1
9 1623657 Nut ......................................................................................................... 14 14
10 d 1623656 Stud ....................................................................................................... 14 14
10 e 1627812 Stud ....................................................................................................... 14 14
11 d 1623659 Plug ........................................................................................................ 2 2
11 e 1627813 Plug ....................................................................................................... 2 2
12 1623652 Bolt ........................................................................................................ 2 2
13 d 1623651 Cap ........................................................................................................ 2 2
13 e 1627806 Cap ........................................................................................................ 2 2
14 d 1623650 Nut ......................................................................................................... 2 2
14 e 1627805 Nut ......................................................................................................... 2 2
15 1627804 Washer .................................................................................................. 2 2
16 1623648 Wheel Hub ............................................................................................ 2 2
17 1623647 Wheel Stud ........................................................................................... 16 16
18 1623646 Bearing (Tapered Roller) ..................................................................... 2 2
19 1623645 Bearing (Tapered Roller) ..................................................................... 2 2
20 1627802 Seal ....................................................................................................... 2 2
21 1623545 Drain Plug (Fluid Drain) ....................................................................... 3 3
22 1623544 Plug (Fluid Check And Fill) ................................................................. 3 3
23 1623643 Bolt ........................................................................................................ 24 24
24 d 1623642 Cover ..................................................................................................... 2 2
24 e 1647657 Cover ..................................................................................................... 2 2
25 1623660 Carrier ................................................................................................... 2 2
26 1623655 O-Ring ............................................................................................... 1 1
26 1689459 O-Ring (Alternate Part) ................................................................... 1 1

©2011 HYSTER COMPANY See Service Manual 6-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DRIVE AXLE HOUSING AND HUB

WET BRAKE
KEY:
A: S80FT
B: S100-120FT
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
27 1623641 Carrier ............................................................................................... 1 1
28 1623640 Bearing ............................................................................................. 4 4
29 1623639 Gear .................................................................................................. 4 4
30 1623638 Retaining Ring ................................................................................. 4 4
31 1623636 Ring Gear ......................................................................................... 1 1
32 1623635 Thrust Washer ................................................................................. 1 1
33 1623637 Dowel .................................................................................................... 8 8
34 1623634 O-Ring ................................................................................................... 2 2
35 d 1623633 Pinion ..................................................................................................... 2 2
35 e 1627799 Pinion .................................................................................................... 2 2
36 1623663 Axle Shaft (Short) .................................................................................. 1 ..
36 1623664 Axle Shaft (Long) ................................................................................... 1 ..
36 1623823 Axle Shaft (Short) ................................................................................ .. 1
36 1623824 Axle Shaft (Long) ................................................................................. .. 1
37 1641354 Plug (Fluid Check And Fill) ................................................................. 1 1
37 1641356 Sealing Ring ..................................................................................... 1 1

FOOTNOTES:
a Diesel with Any Transmission d → S/N G004V01515D
b With Extended Function Dual Speed Transmission e S/N G004V01516D →
c Without Extended Function Dual Speed
Transmission

6-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 6-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DIFFERENTIAL (FIGURE 6-5)

DRY BRAKE

6-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

DIFFERENTIAL
DRY BRAKE

ITEM PART NO. DESCRIPTION QTY

1 2067574 Differential ........................................................................................................... 1
2 1565327 Bolt ................................................................................................................. 8
3 ..... Case Set ......................................................................................................... 1
4 1565325 Washer (Side) ................................................................................................ 2
5 2029383 Spider ............................................................................................................. 1
6 ..... Gear (Pinion) .................................................................................................. 4
7 ..... Washer (Pinion) .............................................................................................. 4
8 ..... Gear (Side) ..................................................................................................... 2
1606531 Kit-Gear (Includes Items 6, 8) ............................................................................. 1
1565324 Kit-Washer (Includes Items 4, 7) ........................................................................ 1

©2011 HYSTER COMPANY See Service Manual 6-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DIFFERENTIAL (FIGURE 6-6)

WET BRAKE

6-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

DIFFERENTIAL
WET BRAKE

ITEM PART NO. DESCRIPTION QTY

fg 2063158 Drive Axle (11.2 Overall Ratio) ........................................................................... 1
fh 2090890 Drive Axle (11.2 Overall Ratio) ........................................................................... 1
deg 2063159 Drive Axle (12.8 Overall Ratio) ........................................................................... 1
deh 2090891 Drive Axle (12.8 Overall Ratio) ........................................................................... 1
cg 2063843 Drive Axle (11.2 Overall Ratio) ........................................................................... 1
ch 2090896 Drive Axle (11.2 Overall Ratio) ......................................................................... 1
abg 2063844 Drive Axle (12.8 Overall Ratio) ........................................................................... 1
abh 2090897 Drive Axle (12.8 Overall Ratio) ........................................................................... 1
1 1623593 Bolt ................................................................................................................ 2
2 g 1623588 Nut .................................................................................................................. 2
2 h 1627793 Nut ................................................................................................................. 2
3 g 1623589 Seal ................................................................................................................ 2
3 h 1627794 Seal ................................................................................................................ 2
4 1623590 Snap Ring ...................................................................................................... 2
5 1623591 O-Ring ........................................................................................................... 2
6 1623592 Bearing .......................................................................................................... 2
7 1623578 Bolt ................................................................................................................ 12
8 1623817 Bevel Gear (12.8 Overall Ratio) ..................................................................... 1
8 1623575 Bevel Gear (11.2 Overall Ratio) ................................................................... 1
9 1623580 Thrust Washer .............................................................................................. 2
10 1623581 Gear ............................................................................................................... 2
11 1623587 Thrust Washer .............................................................................................. 4
12 1623586 Pinion ............................................................................................................ 4
13 1623584 Pin .................................................................................................................. 2
14 1623585 Dowel ............................................................................................................. 3
15 1623583 Pin .................................................................................................................. 1
16 1623579 Differential Carrier ........................................................................................ 1
17 1623582 Retainer ......................................................................................................... 1
18 1623574 O-Ring ........................................................................................................... 1
19 1623573 Bearing .......................................................................................................... 1
20 1623572 Spacer ........................................................................................................... 1
21 g 1623569 Shim ............................................................................................................... 1
21 g 1623570 Shim ............................................................................................................... 1
21 g 1623571 Shim ............................................................................................................... 1
21 h 1627788 Shim ............................................................................................................... 1
21 h 1627789 Shim ............................................................................................................... 1
21 h 1627790 Shim ............................................................................................................... 1
21 h 1641361 Shim ............................................................................................................... 1
22 g 1623576 Plug (Ventilation) ............................................................................................ 1
22 h 1627791 Plug ................................................................................................................ 1
23 1623568 Cover ............................................................................................................. 1
24 g 1623577 Bolt ................................................................................................................. 8
24 h 1627792 Bolt ................................................................................................................ 8
25 1623553 Spacer (5.0 mm) ............................................................................................ 1
25 1623554 Spacer (5.1 mm) ............................................................................................ 1
25 1623555 Spacer (5.2 mm) ............................................................................................ 1
25 1623556 Spacer (5.3 mm) ............................................................................................ 1
25 1623557 Spacer (5.4 mm) ............................................................................................ 1
25 1623558 Spacer (5.5 mm) ............................................................................................ 1
25 1623559 Spacer (5.6 mm) ............................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 6-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DIFFERENTIAL
WET BRAKE

ITEM PART NO. DESCRIPTION QTY

25 1623560 Spacer (5.7 mm) ............................................................................................ 1
25 1623561 Spacer (5.8 mm) ............................................................................................ 1
25 1623562 Spacer (5.9 mm) ............................................................................................ 1
25 1623563 Spacer (3.02 mm) .......................................................................................... 1
25 1623564 Spacer (3.04 mm) .......................................................................................... 1
25 1623565 Spacer (3.06 mm) .......................................................................................... 1
25 1623566 Spacer (3.08 mm) .......................................................................................... 1
25 1623567 Spacer (3.00 mm) .......................................................................................... 1
26 1623552 Bearing .......................................................................................................... 1
27 1623551 Nut ................................................................................................................. 1
28 1623550 Seal ................................................................................................................ 1
29 1623549 Cover Plate .................................................................................................... 1
30 1623548 Retaining Ring .............................................................................................. 1
31 1623547 Flange ............................................................................................................ 1
32 1623546 Plug ................................................................................................................ 1
33 1641362 Bushing ......................................................................................................... 2

FOOTNOTES:
a S100-120FT Diesel with Any Transmission e S80FT With Extended Function Dual Speed
b S100-120FT With Extended Function Dual Speed Transmission
Transmission f S80FT Without Extended Function Dual Speed
c S100-120FT Without Extended Function Dual Transmission
Speed Transmission g → S/N G004V01515D
d S80FT Diesel with Any Transmission h S/N G004V01516D →

6-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 6-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

CARRIER ASSEMBLY (FIGURE 6-7)

DRY BRAKE

6-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

CARRIER ASSEMBLY
DRY BRAKE

ITEM PART NO. DESCRIPTION QTY

1601968 Carrier ................................................................................................................. 1
1 1556800 Thrust Washer ................................................................................................ 1
2 1601967 Carrier ............................................................................................................ 1
3 307284 Retaining Ring ................................................................................................ 1
4 44317 Ball Bearing .................................................................................................... 1
5 58943 Snap Ring ....................................................................................................... 1
6 1601966 Pin .................................................................................................................. 3
7 1556799 Thrust Washer ................................................................................................ 6
8 1633297 Roller .............................................................................................................. 3
9 1601965 Gear ............................................................................................................... 3

©2011 HYSTER COMPANY See Service Manual 6-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

WET BRAKES (FIGURE 6-8)

6-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

WET BRAKES
KEY:
A: S80FT
B: S100-120FT
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
a 2063158 Drive Axle (11.2 Overall Ratio) ................................................................... 1 ..
b 2090890 Drive Axle (11.2 Overall Ratio) ................................................................... 1 ..
a 2063159 Drive Axle (12.8 Overall Ratio) ................................................................... 1 ..
b 2090891 Drive Axle (12.8 Overall Ratio) ................................................................... 1 ..
a 2063843 Drive Axle (11.2 Overall Ratio) ................................................................... .. 1
b 2090896 Drive Axle (11.2 Overall Ratio) ................................................................ .. 1
a 2063844 Drive Axle (12.8 Overall Ratio) ................................................................... .. 1
b 2090897 Drive Axle (12.8 Overall Ratio) ................................................................... .. 1
1 a 1623686 Disk ........................................................................................................ 2 2
1 b 1627823 Disk ....................................................................................................... 2 2
2 1623687 Seal ....................................................................................................... 2 2
3 1623688 Seal ....................................................................................................... 2 2
4 a 1623689 Piston ..................................................................................................... 2 2
4 b 1644455 Piston .................................................................................................... 2 2
5 1623690 Spring ................................................................................................... 6 6
6 1623691 Bolt (Adjusting) .................................................................................... 6 6
7 1627837 Brake Disk ............................................................................................ 2 4
8 1627826 Bolt (Adjusting) .................................................................................... 6 6
9 1623692 Spring .................................................................................................... 6 6
10 a 1627838 Disk (Intermediate) ................................................................................ .. 2
10 b 1644456 Disk (Intermediate) .............................................................................. 2 4
11 1623678 Dowel ..................................................................................................... 8 ..
11 1627822 Dowel .................................................................................................... .. 8
12 1623677 Stud (Bleeding) .................................................................................... 2 2
13 1623676 Plug ....................................................................................................... 2 2
14 1623674 Bearing ................................................................................................. 4 4
15 1623675 Lever (Brake) ........................................................................................ 2 2
16 1623673 O-Ring ................................................................................................... 2 2
17 a 1623697 Bushing (Reduction) .............................................................................. 2 2
17 b 1627836 Bushing (Reduction) ........................................................................... 2 2
18 1623672 Bolt ........................................................................................................ 8 8
19 1623696 Nut ......................................................................................................... 2 2
20 1623695 Bolt (Left) .............................................................................................. 1 1
20 1646920 Bolt (Right) ........................................................................................... 1 1
21 1623671 O-Ring ................................................................................................... 2 2
22 1623670 Lever ..................................................................................................... 2 2
23 1623669 Bolt ........................................................................................................ 2 2
24 1623694 Spacer ................................................................................................... 2 2

FOOTNOTES:
a → S/N G004V01515D b S/N G004V01516D →

©2011 HYSTER COMPANY See Service Manual 6-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

DRIVE TIRE AND WHEEL (FIGURE 6-9)

KEY:
A: S80FT (22x9x16)
B: S100-120FT (22x12x16)
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 a 1539313 Wheel ......................................................................................................... 2 ..
1 b 1539315 Wheel ......................................................................................................... 2 ..
1 a 1539317 Wheel ......................................................................................................... .. 2
1 b 1539319 Wheel ......................................................................................................... .. 2
1 b 2103939 Wheel Assy (Heavy-Duty) .......................................................................... .. 2
1 b 2103940 Wheel Assy (Non-Marking) ........................................................................ .. 2
2 1541525 Cushion Tire (Standard Smooth Tread) ..................................................... 2 ..
2 1655310 Cushion Tire (Smooth Tread Non-Marking Compound) ............................ 2 ..
2 1541527 Cushion Tire (Lug Tread) ........................................................................... 2 ..
2 1541528 Cushion Tire (Standard Smooth Tread) ..................................................... .. 2
2 1655318 Cushion Tire (Smooth Tread Non-Marking Compound) ....................... .. 2
2 1541530 Cushion Tire (Lug Tread) ........................................................................... .. 2
2 b 181482 Tire-Solid Cushion (Heavy Duty) ................................................................ .. 2
2 b 1690958 Cushion Tire (Non-Marking) ....................................................................... .. 2

FOOTNOTES:
a Standard Tread b Wide Tread

6-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

7 STEERING SYSTEM
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 7
STEERING SYSTEM

DESCRIPTION PAGE

STEER AXLE .................................................................................................................................................. 7-8

STEER CYLINDER ......................................................................................................................................... 7-14
STEER TIRES AND WHEELS ........................................................................................................................ 7-16
STEERING COLUMN AND ATTACHING PARTS .......................................................................................... 7-2
STEERING COLUMN ASSEMBLY ................................................................................................................. 7-4
STEERING CONTROL UNIT .......................................................................................................................... 7-6
STEERING LINES ........................................................................................................................................... 7-12

©2011 HYSTER COMPANY See Service Manual 7-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STEERING COLUMN AND ATTACHING PARTS (FIGURE 7-1)

ITEM PART NO. DESCRIPTION QTY

1 1512403 Capscrew ........................................................................................................... 4
2 a 1450503 Horn Button ......................................................................................................... 1
3 1551839 Steering Wheel (Without Spinner Knob) ............................................................. 1
3 1531563 Steering Wheel (With Spinner) ........................................................................ 1
4 1586109 Knob Assembly ............................................................................................ 1
4 1675581 Knob .......................................................................................................... 1
4 1675582 Cap ............................................................................................................ 1
4 1675583 Insert ......................................................................................................... 1
5 b 1544566 Steering Column ................................................................................................. 1
5 c 1657962 Steering Column ................................................................................................. 1
5 d 4023450 Steering Column (FFigure 7-2)....................................................................... 1

FOOTNOTES:
a Service with Horn Replacement Kit 1642089 c 2/2007 ↔ 1/2011
b → 2/2007 d 1/2011 →

7-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 7-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STEERING COLUMN ASSEMBLY (FIGURE 7-2)

7-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

STEERING COLUMN ASSEMBLY

ITEM PART NO. DESCRIPTION QTY
a 1544566 Steering Column ................................................................................................. 1
b 1657962 Steering Column ................................................................................................. 1
c 4023450 Steering Column ............................................................................................... 1
1 1562509 Kit-Support .................................................................................................... 1
2 ..... Support ..................................................................................................... 1
3 ..... Spacer ....................................................................................................... 4
4 ..... Joint ........................................................................................................... 1
5 ..... Nut ............................................................................................................. 2
6 ..... Washer ...................................................................................................... 2
7 ..... Screw ......................................................................................................... 2
8 a 1562489 Kit-Shaft (Upper) ............................................................................................ 1
8 b 1647528 Kit-Shaft (Upper) ............................................................................................ 1
8 c 4028642 Kit (Shaft Upper) ........................................................................................... 1
9 ..... Shaft Assembly (Upper) .......................................................................... 1
10 ..... Housing Assembly ................................................................................... 1
11 1562492 Kit-Nut ........................................................................................................... 1
12 ..... Nut ............................................................................................................. 2
13 1562493 Kit-Shaft (Lower) .......................................................................................... 1
14 ..... Shaft Assembly (Lower) .......................................................................... 1
15 ..... Pin .............................................................................................................. 1
16 1562496 Kit-Contact .................................................................................................... 1
17 ..... Contact Assembly (Horn) ........................................................................ 1
18 ..... Screw ......................................................................................................... 4
19 ..... Fastener .................................................................................................... 1
20 ..... Connector ................................................................................................. 1
21 1562501 Kit-Pivot (Lower) ........................................................................................... 1
22 ..... Bolt (Pivot) ................................................................................................ 2
23 ..... Bushing ..................................................................................................... 2
24 ..... Nut ............................................................................................................. 2
25 1562505 Kit-Gas Spring .............................................................................................. 1
26 ..... Gas Spring ................................................................................................ 1
27 ..... Pin .............................................................................................................. 1
28 ..... Pin .............................................................................................................. 1

FOOTNOTES:
a → 2/2007 c 1/2011 →
b 2/2007 ↔ 1/2011

©2011 HYSTER COMPANY See Service Manual 7-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STEERING CONTROL UNIT (FIGURE 7-3)

7-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

STEERING CONTROL UNIT

ITEM PART NO. DESCRIPTION QTY
a 2063121 Steering Control Unit (100cc) ............................................................................. 1
b 2102565 Steering Control Unit (Alternate Part) ............................................................. 1
1 ..... Dust Seal ....................................................................................................... 1
2 ..... Housing ......................................................................................................... 1
3 ..... Relief Valve ................................................................................................... 1
4 ..... Bushing ......................................................................................................... 1
5 ..... Check Ball ..................................................................................................... 1
6 ..... Check Ball ..................................................................................................... 1
7 ..... Seat ................................................................................................................ 1
8 ..... O-Ring ........................................................................................................... 1
9 ..... Bearing Set ................................................................................................... 1
10 ..... Ring ............................................................................................................... 1
11 ..... Spool ............................................................................................................. 1
12 ..... Pin .................................................................................................................. 1
13 ..... Sleeve ............................................................................................................ 1
14 ..... Spring Set ..................................................................................................... 1
15 ..... Shaft .............................................................................................................. 1
16 ..... O-Ring ........................................................................................................... 3
17 ..... Plate ............................................................................................................... 1
18 ..... Gear Set ......................................................................................................... 1
19 ..... Gear Ring ...................................................................................................... 1
20 ..... Cover ............................................................................................................. 1
21 ..... Washer .......................................................................................................... 7
22 ..... Special Screw ............................................................................................... 2
23 ..... Capscrew ...................................................................................................... 5
24 ..... Priority Valve Plug ........................................................................................ 1
25 ..... Diagnostic Plug (Supply Pressure) ............................................................ 1
26 ..... Cap ................................................................................................................. 1
27 ..... System Relief Valve ..................................................................................... 1
28 ..... O-Ring ....................................................................................................... 1
29 ..... Back-Up Ring ............................................................................................ 1
30 ..... O-Ring ....................................................................................................... 1
31 ..... Cartridge ................................................................................................... 1
32 ..... Seat ............................................................................................................ 1
33 ..... Spring ........................................................................................................ 1
34 ..... Plug ........................................................................................................... 1
35 ..... Anti-Tamper Ring ..................................................................................... 1
36 ..... Snap Ring ................................................................................................. 1
37 1581858 Kit-Capscrew ..................................................................................................... 1
1579908 Kit-Seal (Includes Items 1, 8, 16, 21, 28-30, 34) ................................................ 1
b 1676606 Kit (Load Sense Alteration Kit) ............................................................................ 1

FOOTNOTES:
a → 9/2007 b 9/2007 →

©2011 HYSTER COMPANY See Service Manual 7-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STEER AXLE (FIGURE 7-4)

7-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

STEER AXLE
ITEM PART NO. DESCRIPTION QTY
1552973 Steering Axle ..................................................................................................... 1
1 1581295 Steering Axle ................................................................................................ 1
1 2073193 Frame ........................................................................................................ 1
2 1507047 Spindle (LH) .................................................................................................. 1
3 13963 Grease Fitting ........................................................................................... 2
4 1388829 Dust Cap ................................................................................................... 2
5 153716 Seal ................................................................................................................ 2
6 230421 Bearing Cup .................................................................................................. 2
7 153715 Bearing Cone ................................................................................................ 2
8 153717 Wear Sleeve .................................................................................................. 2
9 15235 Cotter Pin ...................................................................................................... 2
10 21110 Nut ................................................................................................................. 2
11 1508022 Washer .......................................................................................................... 2
12 1507393 Spindle (RH) .................................................................................................. 1
13 266733 Seal ................................................................................................................ 2
14 1507898 Tie Rod (Assembly) ...................................................................................... 2
15 1507561 Tie Rod ...................................................................................................... 1
16 185872 Bushing ..................................................................................................... 1
17 13957 Grease Fitting ............................................................................................. 1
18 127045 Clamp (Hose) ................................................................................................ 2
19 185869 Boot ............................................................................................................... 2
20 119236 Clamp ............................................................................................................ 2
21 58903 Snap Ring ...................................................................................................... 4
22 1568271 Pin .................................................................................................................. 2
23 293686 Capscrew ...................................................................................................... 8
24 2071097 Steering Cylinder (FFigure 7-6).................................................................. 1
25 293628 Capscrew ...................................................................................................... 6
26 266728 Seal ................................................................................................................ 2
27 135657 Bearing Cone ................................................................................................ 2
28 135658 Bearing Cup .................................................................................................. 2
29 39678 O-Ring ........................................................................................................... 2
30 185856 Shim (0.005 in.) ............................................................................................. AR
30 185857 Shim (0.007 in.) ............................................................................................. AR
30 185858 Shim (0.020 in.) ............................................................................................. AR
31 370467 Bearing Cap (Assembly) ................................................................................ 1
31 1374823 Bearing Set ............................................................................................... 1
31 4006723 Bearing Set ............................................................................................... 1
32 370466 Bearing Cap .............................................................................................. 2
33 16009 Grease Fitting ........................................................................................... 2
34 1525354 Rubber Mount ................................................................................................... 2
35 a 293648 Capscrew (Alternate Part) .................................................................................. 4
35 a 1569751 Capscrew ............................................................................................................ 4
35 b 293686 Capscrew ........................................................................................................... 4
36 a 320161 Washer (Alternate Part) .................................................................................... 4
36 b 296426 Washer ............................................................................................................... 8
37 a 300937 Nut (Alternate Part) ............................................................................................. 4
37 b 316828 Nut ...................................................................................................................... 4
38 1582299 Plate (Alternate Part) ........................................................................................ 2
38 1543254 Plate .................................................................................................................... 2
39 69029 Cap ..................................................................................................................... 2
40 1383777 Nut ...................................................................................................................... 2

©2011 HYSTER COMPANY See Service Manual 7-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STEER AXLE
ITEM PART NO. DESCRIPTION QTY
41 56997 Cotter Pin ........................................................................................................... 2
42 1383775 Washer ............................................................................................................... 2
43 153835 Bearing Cone .................................................................................................... 2
44 153834 Bearing Cup ...................................................................................................... 2
45 30147 Bearing Cup ...................................................................................................... 2
46 230315 Bearing Cone .................................................................................................... 2
47 44542 Seal .................................................................................................................... 2
48 164639 Wear Sleeve ....................................................................................................... 2
49 352205 Rubber Mount ................................................................................................... 2
2064554 Loctite ................................................................................................................ AR

FOOTNOTES:
a → S/N G004V04544G INC. 04562-04563 b S/N G004V04544G → EXC. 04562-04563

7-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 7-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STEERING LINES (FIGURE 7-5)

7-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

STEERING LINES
ITEM PART NO. DESCRIPTION QTY
1 4022956 Fitting .................................................................................................................. 2
2 4022958 Fitting .................................................................................................................. 2
3 1527879 Capscrew ............................................................................................................ 6
4 1544157 Clip ...................................................................................................................... 6
5 bc 2085764 Hose Assy ........................................................................................................... 1
5 bd 2103676 Hose Assy (Alternate Part) ................................................................................. 1
5 ac 2085765 Hose Assy ........................................................................................................... 1
5 ad 2104071 Hose Assy (Alternate Part) ................................................................................. 1
6 b 1486740 Fitting .................................................................................................................. 2
6 b 265787 O-Ring ............................................................................................................ 2
6 a 265731 O-Ring ............................................................................................................ 2
6 a 1486745 Fitting .................................................................................................................. 2
6 16483 O-Ring ............................................................................................................ 2
7 bc 2085766 Hose Assy ........................................................................................................... 1
7 bd 2103806 Hose Assy (Alternate Part) ................................................................................. 1
7 ac 2085767 Hose Assy ........................................................................................................... 1
7 ad 2104072 Hose Assy (Alternate Part) ................................................................................. 1
8 1480237 Nut ...................................................................................................................... 6

FOOTNOTES:
a S100-120FT, 120FTS, 120PRS c → PENDING PER ECN 105402
b S80FT, S80BCS, S100BCS d PENDING PER ECN 105402 →

©2011 HYSTER COMPANY See Service Manual 7-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STEER CYLINDER (FIGURE 7-6)

7-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

STEER CYLINDER
ITEM PART NO. DESCRIPTION QTY
2071097 Steering Cylinder .............................................................................................. 1
1 370415 Cylinder Rod ................................................................................................. 1
2 2071094 Rod Wiper ..................................................................................................... 2
3 1380092 Rod Seal ........................................................................................................ 2
4 1561005 End Cap ......................................................................................................... 1
5 268619 O-Ring ........................................................................................................... 2
6 147973 Back-Up Ring ................................................................................................ 2
7 118358 O-Ring ........................................................................................................... 2
8 370414 Tube Wldmt-Cylinder ................................................................................... 1
9 2044371 Piston Seal .................................................................................................... 1
1566700 Kit-Seal (Includes Items 2-3, 5-7, 9) ................................................................... 1

©2011 HYSTER COMPANY See Service Manual 7-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STEER TIRES AND WHEELS (FIGURE 7-7)

KEY:
A: 18 x 7 x 12 .12 Solid Cushion
B: 18 x 8 x 12.12 Solid Cushion
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 370444 Wheel ......................................................................................................... 2 2
2 b 1541486 Cushion Tire (Smooth) ............................................................................... 2 ..
2 b 1655317 Cushion Tire (Non-Marking) ....................................................................... 2 ..
2 b 1541490 Cushion Tire (Lug) ..................................................................................... 2 ..
2 a 1541546 Cushion Tire (Smooth) ............................................................................... .. 2
2 a 1541547 Cushion Tire (Lug) ..................................................................................... .. 2
2 a 1655315 Cushion Tire (Non-Marking) .................................................................... .. 2

FOOTNOTES:
a S100-120FT b S80FT

7-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

8 BRAKE SYSTEM
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 8
BRAKE SYSTEM

DESCRIPTION PAGE

BRAKE ASSEMBLY
S100-120FT, S120FTS, S120FTPRS - DRY BRAKE ................................................................................. 8-4
S80FT, S80-100FTBCS - DRY BRAKE ...................................................................................................... 8-2
BRAKE COOLING SYSTEM
SINGLE AND DUAL PEDAL - WET BRAKE (→ S/N G004V01514D) ....................................................... 8-26
SINGLE AND DUAL PEDAL - WET BRAKE (S/N G004V01515D →) ....................................................... 8-28
BRAKE LINKAGE
DUAL PEDAL - DRY BRAKE ...................................................................................................................... 8-10
DUAL PEDAL - WET BRAKE ...................................................................................................................... 8-18
SINGLE PEDAL - DRY BRAKE .................................................................................................................. 8-6
SINGLE PEDAL - WET BRAKE .................................................................................................................. 8-14
BRAKE MASTER CYLINDER ASSEMBLY ..................................................................................................... 8-21
PARKING BRAKE ASSEMBLY ....................................................................................................................... 8-24

©2011 HYSTER COMPANY See Service Manual 8-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE ASSEMBLY (FIGURE 8-1)

S80FT, S80-100FTBCS — DRY BRAKE

8-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BRAKE ASSEMBLY
S80FT, S80-100FTBCS – DRY BRAKE
KEY:
A: Left Hand
B: Right Hand
QTY
ITEM PART NO. DESCRIPTION A B
a 1633017
1641955
1688564 Brake Assembly ......................................................................................... 1 ..
b 1633017
1641955
1688564 Brake Assembly ......................................................................................... 1 ..
a 1633018
1641956
1688565 Brake and Cable Assy ................................................................................ .. 1
b 1633018
1641956
1688565 Brake Assembly ......................................................................................... .. 1
a 1627106 Brake Assembly (Without Cable) ........................................................... 1 ..
b 1643385
1688568 Brake Assembly (Without Cable) ........................................................... 1 ..
a 1627107 Brake Assembly (Without Cable) ........................................................... .. 1
b 1688569 Brake Assembly (Without Cable) ........................................................... .. 1
1 1627124 Backplate ........................................................................................... 1 ..
1 1627125 Backplate ........................................................................................... .. 1
2 ..... Retainer ......................................................................................... 1 1
3 ..... Bolt ................................................................................................ 2 2
4 292680 Washer .......................................................................................... 2 2
5 1627122
1688572 Kit-Spring ........................................................................................... 1 1
6 a 1627114 Kit-Brake Shoe .................................................................................. 1 ..
6 b 1643387 Kit-Brake Shoe .................................................................................. 1 ..
6 a 1627115 Kit-Brake Shoe .................................................................................. .. 1
6 b 1643388 Kit-Brake Shoe .................................................................................. .. 1
7 1627118 Wheel Cylinder .................................................................................. 1 1
8 a 1627120 Kit-Adjuster ........................................................................................ 1 1
8 b 1643380 Kit-Adjuster ........................................................................................ 1 1
9 1627151
1688555 Parking Brake Cable .............................................................................. 1 ..
9 1627152
1688556 Parking Brake Cable .............................................................................. .. 1

FOOTNOTES:
a → S/N G004V01514D b S/N G004V01515D →

©2011 HYSTER COMPANY See Service Manual 8-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE ASSEMBLY (FIGURE 8-2)

S100-120FT, S120FTS, S120FTPRS — DRY BRAKE

8-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BRAKE ASSEMBLY
S100-120FT, S120FTS, S120FTPRS – DRY BRAKE
KEY:
A: Left Hand
B: Right Hand
QTY
ITEM PART NO. DESCRIPTION A B
b 1633124
1641953
1688551 Brake Assembly (LH) ................................................................................. 1 ..
d 1633124
1641953
1688551 Brake Assembly (LH) ................................................................................. 1 ..
b 1633125
1641954
1688552 Brake Assembly (RH) ................................................................................. .. 1
d 1633125
1641954
1688552 Brake Assembly (RH) ................................................................................. .. 1
b 1627110 Brake Assembly (Without Cable) ........................................................... 1 ..
d 1643376
1688557 Brake Assembly (Without Cable) ........................................................... 1 ..
b 1627111 Brake Assembly (Without Cable) ........................................................... .. 1
d 1643377
1688558 Brake Assembly (Without Cable) ........................................................... .. 1
1 1627128 Backplate ........................................................................................... 1 ..
1 1627129 Backplate ........................................................................................... .. 1
2 ..... Retainer ......................................................................................... 1 1
3 ..... Bolt ................................................................................................ 2 2
4 292680 Washer .......................................................................................... 2 2
5 1627123
1688561 Kit-Spring ........................................................................................... 1 1
6 c 1627117 Kit-Brake Shoe .................................................................................. .. 1
6 e 1643379 Kit-Brake Shoe .................................................................................. .. 1
6 c 1627116 Kit-Brake Shoe .................................................................................. 1 ..
6 e 1643378 Kit-Brake Shoe .................................................................................. 1 ..
7 c 1635218 Kit-Adjuster ........................................................................................ 1 1
7 e 1643399 Kit-Adjuster ........................................................................................ 1 1
8 ..... Washer .......................................................................................... 2 2
9 ..... Bolt ................................................................................................ 1 1
10 a 1627119 Kit-Repair Wheel Cylinder ................................................................. 1 1
11 1627151
1688555 Parking Brake Cable (LH) ...................................................................... 1 ..
11 1627152
1688556 Parking Brake Cable (RH) ..................................................................... .. 1

FOOTNOTES:
a Includes Wheel Cylinder, Bleed Valve, Spring d S/N G004V01515D →
Washer and Bolt e S/N G004V01516D →
b → S/N G004V01514D
c → S/N G004V01515D

©2011 HYSTER COMPANY See Service Manual 8-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE LINKAGE (FIGURE 8-3)

SINGLE PEDAL — DRY BRAKE

8-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BRAKE LINKAGE
SINGLE PEDAL – DRY BRAKE

ITEM PART NO. DESCRIPTION QTY

1 302398 Locknut ............................................................................................................... 2
2 1531567 Bracket (Inching Sensor) .................................................................................... 1
3 1553897 Capscrew ............................................................................................................ 2
4 1547849 Sensor (Brake Position) ...................................................................................... 1
5 1586627 Capscrew ............................................................................................................ 2
6 1500912 Clip ...................................................................................................................... 1
7 1564526 Clip (Key Hole) .................................................................................................... 1
8 1623904 Bracket Wldmt .................................................................................................... 1
9 1529366 Capscrew ............................................................................................................ 1
10 1514429 Nut ...................................................................................................................... 1
11 1527879 Capscrew ............................................................................................................ 2
12 1510126 Screw (Button Head) .......................................................................................... 1
13 2021353 Holder ................................................................................................................. 1
14 1510113 Capscrew ............................................................................................................ 2
15 1530243 Insert ................................................................................................................... 2
16 1543698 Clamp (Swivel) .................................................................................................... 2
17 1543842 Clamp ................................................................................................................. 1
18 1585575 Bushing ............................................................................................................... 2
19 2064554 Loctite ................................................................................................................. AR
20 1594950 Bracket ................................................................................................................ 1
21 1646439 Reservoir ............................................................................................................ 1
21 2077604 Tank ............................................................................................................... 1
21 f 1646557 Diaphragm ...................................................................................................... 1
21 k 1645381 Diaphragm ...................................................................................................... 1
21 1646397 Cap ................................................................................................................. 1
22 1568075 Spring (RH) ......................................................................................................... 1
23 233683 Fitting .................................................................................................................. 1
23 16487 O-Ring ............................................................................................................ 1
24 2092888 Hose (Upper Brake Feed) ................................................................................... 1
25 1556475 Bumper ............................................................................................................... 1
26 239503 Nut ...................................................................................................................... 1
27 1534871 Bolt ...................................................................................................................... 1
28 a 1641557 Pedal (S80FT) .................................................................................................... 1
28 1641555 Pedal (S100-120FT) ........................................................................................... 1
29 1570298 Rubber Pad ......................................................................................................... 1
30 1516199 Fitting .................................................................................................................. 1
30 265787 O-Ring ............................................................................................................ 1
30 16483 O-Ring ............................................................................................................ 1
31 2091015 Hose Assy ........................................................................................................... 1
32 1487061 Fitting .................................................................................................................. 1
32 16484 O-Ring ............................................................................................................ 1
32 265787 O-Ring ............................................................................................................ 1
33 1487066 Fitting .................................................................................................................. 1
33 265731 O-Ring ............................................................................................................ 1
33 16486 O-Ring ............................................................................................................ 1
34 e 164289 Hose ................................................................................................................... 1
34 j 112385 Hose ................................................................................................................... 1
35 222501 Fitting .................................................................................................................. 1
35 16483 O-Ring ............................................................................................................ 1
36 2074167 Hose Assy (Brake) .............................................................................................. 1

©2011 HYSTER COMPANY See Service Manual 8-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE LINKAGE
SINGLE PEDAL – DRY BRAKE

ITEM PART NO. DESCRIPTION QTY

37 1590033 Transducer .......................................................................................................... 1
38 1487058 Fitting .................................................................................................................. 1
38 1527813 O-Ring ............................................................................................................ 1
38 16481 O-Ring ............................................................................................................ 1
39 g 1573675 Brake Booster (FFigure 8-7).............................................................................. 1
39 h 2096079 Master Cylinder (FFigure 8-7)........................................................................... 1
39 i 2110224 Master Cylinder (FFigure 8-7)........................................................................... 1
40 1527880 Capscrew ............................................................................................................ 2
41 1351689 Lockring .............................................................................................................. 1
42 1375391 Pin (Rod End) ..................................................................................................... 1
43 166857 Clamp ................................................................................................................. 4
43 c 168718 Clamp ................................................................................................................. 4
44 222509 Fitting .................................................................................................................. 1
44 16481 O-Ring ............................................................................................................ 1
45 d 77186 Fitting .................................................................................................................. 1
45 16487 O-Ring ............................................................................................................ 1
46 2092613 Cylinder Block ..................................................................................................... 1
47 117989 Hose ................................................................................................................... 1
48 1527876 Capscrew ............................................................................................................ 1
49 222491 Fitting .................................................................................................................. 1
49 16481 O-Ring ............................................................................................................ 1
b 2093224 Label (Brake Fluid Warning) ............................................................................... 1
b 114312 Strap Clamp ........................................................................................................ 1

FOOTNOTES:
a Also used with BCS g → S/N G004V02252E
b Not Illustrated h S/N G004V02253E ↔ S/N G004V04503G INC.
c Optional 02127
d → 9/2007 i S/N G004V04504G →
e → PENDING PER ECN 104796 j 9/8007 →
f → S/N G004V01834D k S/N G004V01835D →

8-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 8-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE LINKAGE (FIGURE 8-4)

DUAL PEDAL — DRY BRAKE

8-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BRAKE LINKAGE
DUAL PEDAL – DRY BRAKE

ITEM PART NO. DESCRIPTION QTY

1 302398 Locknut ............................................................................................................... 2
2 1531567 Bracket (Inching Sensor) .................................................................................... 1
3 1553897 Capscrew ............................................................................................................ 2
4 1547849 Sensor (Brake Position) ...................................................................................... 1
5 1586627 Capscrew ............................................................................................................ 2
6 1500912 Clip (Connector) .................................................................................................. 1
7 1510113 Capscrew ............................................................................................................ 2
8 1564526 Clip (Key Hole) .................................................................................................... 1
9 1623904 Bracket Wldmt .................................................................................................... 1
10 1556475 Bumper ............................................................................................................... 1
11 1529366 Capscrew ............................................................................................................ 1
12 1514429 Nut ...................................................................................................................... 1
13 1527879 Capscrew ............................................................................................................ 6
14 1510126 Screw (Button Head) .......................................................................................... 1
15 2021353 Holder ................................................................................................................. 1
16 1594950 Bracket ................................................................................................................ 1
17 1646439 Reservoir ............................................................................................................ 1
17 2077604 Tank ............................................................................................................... 1
17 f 1646557 Diaphragm ...................................................................................................... 1
17 k 1645381 Diaphragm ...................................................................................................... 1
17 1646397 Cap ................................................................................................................. 1
18 166857 Clamp ................................................................................................................. 4
18 c 168718 Clamp ................................................................................................................. 4
19 206 Woodruff Key ...................................................................................................... 1
20 12929 Snap Ring ........................................................................................................... 1
21 2073192 Hose Assy (Brake) .............................................................................................. 1
22 1585575 Bushing ............................................................................................................... 2
23 2064554 Loctite ................................................................................................................. AR
24 1568076 Spring (RH) ......................................................................................................... 1
25 a 1568256 Brake Pedal (RH) ................................................................................................ 1
26 1570300 Pad ..................................................................................................................... 2
27 1639801 Brake Pedal (LH) ................................................................................................ 1
28 239503 Nut ...................................................................................................................... 1
29 2092888 Hose (Upper Brake Feed) ................................................................................... 1
30 1516199 Fitting .................................................................................................................. 1
30 265787 O-Ring ............................................................................................................ 1
30 16483 O-Ring ............................................................................................................ 1
31 2091015 Hose Assy ........................................................................................................... 1
32 1487061 Fitting .................................................................................................................. 1
32 16484 O-Ring ............................................................................................................ 1
32 265787 O-Ring ............................................................................................................ 1
33 1487066 Fitting .................................................................................................................. 1
33 16486 O-Ring ............................................................................................................ 1
33 265731 O-Ring ............................................................................................................ 1
34 d 164289 Hose ................................................................................................................... 1
34 j 112385 Hose ................................................................................................................... 1
35 222501 Fitting .................................................................................................................. 1
35 16483 O-Ring ............................................................................................................ 1
36 2074167 Hose Assy ........................................................................................................... 1
37 1590033 Transducer .......................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 8-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE LINKAGE
DUAL PEDAL – DRY BRAKE

ITEM PART NO. DESCRIPTION QTY

38 1487058 Fitting .................................................................................................................. 1
38 1527813 O-Ring ............................................................................................................ 1
38 16481 O-Ring ............................................................................................................ 1
39 g 1573675 Brake Booster (FFigure 8-7).............................................................................. 1
39 h 2096079 Master Cylinder (FFigure 8-7)........................................................................... 1
39 i 2110224 Master Cylinder (FFigure 8-7)........................................................................... 1
40 1527880 Capscrew ............................................................................................................ 2
41 1351689 Lockring .............................................................................................................. 1
42 1375391 Pin (Rod End) ..................................................................................................... 1
43 1530243 Insert ................................................................................................................... 2
44 244540 Bushing ............................................................................................................... 2
45 1568077 Spring (LH) ......................................................................................................... 1
46 1543842 Clamp ................................................................................................................. 1
47 1543698 Clamp (Swivel) .................................................................................................... 1
48 1534871 Bolt ...................................................................................................................... 1
49 1568253 Crank (S100-120FT) ........................................................................................... 1
49 a 1581193 Crank (S80FT) .................................................................................................... 1
50 222509 Fitting .................................................................................................................. 1
50 16481 O-Ring ............................................................................................................ 1
51 233683 Fitting .................................................................................................................. 1
51 16487 O-Ring ............................................................................................................ 1
52 2092613 Cylinder Block ..................................................................................................... 1
53 117989 Hose ................................................................................................................... 1
54 1527876 Capscrew ............................................................................................................ 1
55 222491 Fitting .................................................................................................................. 1
55 16481 O-Ring ............................................................................................................ 1
56 e 77186 Fitting .................................................................................................................. 1
56 16487 O-Ring ............................................................................................................ 1
b 2093224 Label (Brake Fluid Warning) ............................................................................... 1
b 114312 Strap Clamp ........................................................................................................ 1

FOOTNOTES:
a Also used with BCS g → S/N G004V02252E
b Not Illustrated h S/N G004V02253E ↔ S/N G004V04503G INC.
c Optional 02127
d → 9/2007 i S/N G004V04504G →
e → PENDING PER ECN 104796 j 9/2007 →
f → S/N G004V01834D k S/N G004V01835D →

8-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 8-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE LINKAGE (FIGURE 8-5)

SINGLE PEDAL — WET BRAKE

8-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BRAKE LINKAGE
SINGLE PEDAL – WET BRAKE

ITEM PART NO. DESCRIPTION QTY

1 302398 Locknut .............................................................................................................. 2
2 1531567 Bracket (Inching Sensor) ................................................................................. 1
3 1553897 Capscrew ........................................................................................................... 2
4 1547849 Sensor (Brake Position) ................................................................................... 1
5 1586627 Capscrew ........................................................................................................... 2
6 1500912 Clip ..................................................................................................................... 1
7 1564526 Clip (Key Hole) .................................................................................................. 1
8 1623904 Bracket Wldmt .................................................................................................... 1
9 1529366 Capscrew ........................................................................................................... 1
10 1514429 Nut ...................................................................................................................... 1
11 1527879 Capscrew ........................................................................................................... 6
12 1510126 Screw (Button Head) ........................................................................................ 1
13 2021353 Holder ................................................................................................................ 1
14 1583611 Capscrew ........................................................................................................... 2
15 1530243 Insert .................................................................................................................. 2
16 1543698 Clamp (Swivel) .................................................................................................. 1
17 1543842 Clamp ................................................................................................................. 1
18 1585575 Bushing ............................................................................................................. 2
19 1594950 Bracket ............................................................................................................... 1
20 1646439 Reservoir ........................................................................................................... 1
20 2077604 Tank ............................................................................................................... 1
20 c 1646557 Diaphragm ...................................................................................................... 1
20 i 1645381 Diaphragm ..................................................................................................... 1
20 1646397 Cap ................................................................................................................. 1
21 1568075 Spring (RH) ........................................................................................................ 1
22 166857 Clamp ................................................................................................................. 4
22 b 168718 Clamp ................................................................................................................. 4
23 2092888 Hose (Upper Brake Feed) ................................................................................. 1
24 1556475 Bumper .............................................................................................................. 1
25 239503 Nut ...................................................................................................................... 1
26 1534871 Bolt ..................................................................................................................... 1
27 2064554 Loctite ................................................................................................................ AR
28 1641556 Pedal .................................................................................................................. 1
29 1570298 Rubber Pad ........................................................................................................ 1
30 1590033 Transducer ........................................................................................................ 1
31 d 1573675 Brake Booster (S80FT) (FFigure 8-7)................................................................ 1
31 f 2096079 Master Cylinder (S80FT) (FFigure 8-7)............................................................. 1
31 e 1569527 Master Cylinder (S100-120FT) (FFigure 8-7).................................................... 1
31 g 1703607 Master Cylinder (S80FT) (FFigure 8-7)........................................................... 1
31 h 2110224 Master Cylinder (S100-120FT) (FFigure 8-7).................................................... 1
32 1527880 Capscrew ........................................................................................................... 4
33 1351689 Lockring ............................................................................................................. 1
34 1375391 Pin (Rod End) .................................................................................................... 1
35 117989 Hose (Lower Brake Feed) ................................................................................. 1
36 2092613 Cylinder Block ................................................................................................... 1
37 222509 Fitting ................................................................................................................. 1
37 16481 O-Ring ........................................................................................................... 1
38 233683 Fitting ................................................................................................................. 1
38 16487 O-Ring ........................................................................................................... 1
39 222491 Fitting ................................................................................................................. 1

©2011 HYSTER COMPANY See Service Manual 8-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE LINKAGE
SINGLE PEDAL – WET BRAKE

ITEM PART NO. DESCRIPTION QTY

39 16481 O-Ring ........................................................................................................... 1
40 1527876 Capscrew ........................................................................................................... 1
a 2093224 Label (Brake Fluid Warning) ............................................................................... 1
a 114312 Strap Clamp ....................................................................................................... 1

FOOTNOTES:
a Not Illustrated f S/N G004V02253E ↔ S/N G004V04503G INC.
b Optional 02127
c → S/N G004V01834D g S/N G004V04391G →
d → S/N G004V02252E h S/N G004V04504G →
e → S/N G004V04390G i S/N G004V01835D →

8-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 8-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE LINKAGE (FIGURE 8-6)

DUAL PEDAL — WET BRAKE

8-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BRAKE LINKAGE
DUAL PEDAL – WET BRAKE

ITEM PART NO. DESCRIPTION QTY

1 302398 Locknut .............................................................................................................. 2
2 1531567 Bracket (Inching Sensor) ................................................................................. 1
3 1553897 Capscrew ........................................................................................................... 2
4 1547849 Sensor (Brake Position) ................................................................................... 1
5 1586627 Capscrew ........................................................................................................... 2
6 1500912 Clip (Connector) ................................................................................................ 1
7 1583611 Capscrew ........................................................................................................... 2
8 1564526 Clip (Key Hole) .................................................................................................. 1
9 1623904 Bracket Wldmt .................................................................................................... 1
10 1556475 Bumper .............................................................................................................. 1
11 1529366 Capscrew ........................................................................................................... 1
12 1514429 Nut ...................................................................................................................... 1
13 1527879 Capscrew ........................................................................................................... 6
14 1510126 Screw (Button Head) ........................................................................................ 1
15 2021353 Holder ................................................................................................................ 1
16 1594950 Bracket ............................................................................................................... 1
17 1646439 Reservoir ........................................................................................................... 1
17 1646397 Cap ................................................................................................................. 1
17 c 1646557 Diaphragm ...................................................................................................... 1
17 i 1645381 Diaphragm ..................................................................................................... 1
17 2077604 Tank ............................................................................................................... 1
18 166857 Clamp ................................................................................................................. 4
18 b 168718 Clamp ................................................................................................................. 4
19 206 Woodruff Key ...................................................................................................... 1
20 12929 Snap Ring ........................................................................................................... 1
21 1585575 Bushing ............................................................................................................. 2
22 2064554 Loctite ................................................................................................................ AR
23 1568076 Spring (RH) ......................................................................................................... 1
24 1568256 Brake Pedal (RH) ................................................................................................ 1
25 1570300 Pad ..................................................................................................................... 2
26 1639801 Brake Pedal (LH) ................................................................................................ 1
27 239503 Nut ...................................................................................................................... 1
28 2092888 Hose (Upper Brake Feed) ................................................................................. 1
29 1590033 Transducer ........................................................................................................ 1
30 d 1573675 Brake Booster (S80FTS) (FFigure 8-7)............................................................. 1
30 f 2096079 Master Cylinder (S80FTS) (FFigure 8-7)........................................................... 1
30 e 1569527 Master Cylinder (S100-120FTS) (FFigure 8-7).................................................. 1
30 h 2110224 Master Cylinder (S80FTS) (FFigure 8-7)........................................................... 1
30 g 1703607 Master Cylinder (S100-120FTS) (FFigure 8-7)............................................... 1
31 1527880 Capscrew ........................................................................................................... 4
32 1351689 Lockring ............................................................................................................. 1
33 1375391 Pin (Rod End) .................................................................................................... 1
34 1530243 Insert .................................................................................................................. 2
35 244540 Bushing ............................................................................................................... 2
36 1568077 Spring (LH) ......................................................................................................... 1
37 1543842 Clamp ................................................................................................................. 1
38 1543698 Clamp (Swivel) .................................................................................................. 1
39 1534871 Bolt ..................................................................................................................... 1
40 1578922 Crank .................................................................................................................. 1
41 117989 Hose (Lower Brake Feed) ................................................................................. 1

©2011 HYSTER COMPANY See Service Manual 8-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE LINKAGE
DUAL PEDAL – WET BRAKE

ITEM PART NO. DESCRIPTION QTY

42 222509 Fitting ................................................................................................................. 1
42 16481 O-Ring ........................................................................................................... 1
43 2092613 Cylinder Block ................................................................................................... 1
44 222491 Fitting ................................................................................................................. 1
44 16481 O-Ring ........................................................................................................... 1
45 1527876 Capscrew ........................................................................................................... 1
46 233683 Fitting ................................................................................................................. 1
46 16487 O-Ring ........................................................................................................... 1
a 2093224 Label (Brake Fluid Warning) ............................................................................... 1
a 114312 Strap Clamp ....................................................................................................... 1

FOOTNOTES:
a Not Illustrated f S/N G004V02253E ↔ S/N G004V04503G INC.
b Optional 02127
c → S/N G004V01834D g S/N G004V04391G →
d → S/N G004V02252E h S/N G004V04504G →
e → S/N G004V04390G i S/N G004V01835D →

8-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BRAKE MASTER CYLINDER ASSEMBLY (FIGURE 8-7)

KEY:
A: 1573675
B: 2096079 and 2110224
C: 1569527 and 1703607
QTY
ITEM PART NO. DESCRIPTION A B C
b 1573675 Brake Booster (S80, S100-120) ........................................................ 1 .. ..
d 2096079 Master Cylinder (S80, S100-120) ...................................................... .. 1 ..
f 2110224 Master Cylinder (S80, S100-120) ...................................................... .. 1 ..
c 1569527 Master Cylinder (S100-120) .............................................................. .. .. 1
e 1703607 Master Cylinder (S100-120) ............................................................ .. .. 1
1 ..... Booster ......................................................................................... 1 .. ..
1 1670332 Brake Booster .............................................................................. .. 1 1
1 1692229 Kit-Repair Brake Booster ....................................................... .. 1 1
2 1670333 Master Cylinder ............................................................................. 1 1 ..
2 1670334 Master Cylinder ........................................................................... .. .. 1
2 ..... Housing ................................................................................... 1 1 1
3 ..... Spring ...................................................................................... 1 1 1
4 ..... Retainer ................................................................................... 1 1 1
5 ..... Seal (Pressure) ........................................................................ 1 1 1
6 ..... Washer ..................................................................................... 1 1 1
7 ..... Piston ....................................................................................... 1 1 1
8 ..... Seal (Retaining) ....................................................................... 1 1 1
9 ..... Snap Ring ................................................................................ 1 1 1

©2011 HYSTER COMPANY See Service Manual 8-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

KEY:
A: 1573675
B: 2096079 and 2110224
C: 1569527 and 1703607
QTY
ITEM PART NO. DESCRIPTION A B C
a 1596179 Kit-Repair Master Cylinder (S80, S100-120) (Includes Items 4, 6-7,
9) ....................................................................................................... 1 1 ..
1596180 Kit-Repair Minor-Master Cyl (S80, S100-120) (Includes Items 3, 5,
8) ................................................................................................... 1 1 ..
a 1620023 Kit-Repair Major-Master Cyl (S100-120) (Includes Items 4, 6-7,
9) ....................................................................................................... .. .. 1
1620024 Kit-Repair Minor-Master Cyl (S100-120) (Includes Items 3, 5,
8) ................................................................................................... .. .. 1

FOOTNOTES:
a Includes Minor Repair Kit d S/N G004V02253E ↔ S/N G004V04503G INC.
b → S/N G004V02252E 02127
c → S/N G004V04390G e S/N G004V04391G →
f S/N G004V04504G →

8-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 8-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

PARKING BRAKE ASSEMBLY (FIGURE 8-8)

8-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

PARKING BRAKE ASSEMBLY

KEY:
A: With Wet Brakes
B: With Dry Brakes
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1654321 Parking Brake Assy ................................................................................. 1 1
1 1654322 Parking Brake Lever Assy .................................................................. 1 1
1 1583915 Grip ................................................................................................... 1 1
2 1547849 Sensor (Brake Position) ...................................................................... 1 1
3 1500912 Clip ........................................................................................................ 1 1
4 1564526 Clip (Key Hole) ..................................................................................... 1 1
5 1553897 Capscrew .............................................................................................. 2 2
6 1529366 Capscrew .................................................................................................. 4 4
7 2092505 Parking Brake Cable (LH) ........................................................................ 1 ..
7 2092506 Parking Brake Cable (RH) ........................................................................ 1 ..
7 1627151
1688555 Parking Brake Cable (LH) .......................................................................... .. 1
7 1627152
1688556 Parking Brake Cable (RH) .......................................................................... .. 1
8 1326653 Clamp ........................................................................................................ 3 ..
9 1637399 Bracket ...................................................................................................... 1 ..
10 1398062 Nut ............................................................................................................. 1 ..
11 1527880 Capscrew .................................................................................................. 1 ..
12 1528778 Capscrew ................................................................................................... 3 ..
13 1375391 Pin (Rod End) ........................................................................................... 2 2
14 1351689 Lockring .................................................................................................... 2 2

©2011 HYSTER COMPANY See Service Manual 8-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE COOLING SYSTEM (FIGURE 8-9)

SINGLE AND DUAL PEDAL — WET BRAKE (→ S/N G004V01514D)

8-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BRAKE COOLING SYSTEM

SINGLE AND DUAL PEDAL – WET BRAKE (→ S/N G004V01514D)

ITEM PART NO. DESCRIPTION QTY

1 1516199 Fitting .................................................................................................................. 1
1 16483 O-Ring ............................................................................................................ 1
1 265787 O-Ring ............................................................................................................ 1
2 2074785 Hose Assy ........................................................................................................... 1
3 1487061 Fitting .................................................................................................................. 2
3 16484 O-Ring ............................................................................................................ 1
3 265787 O-Ring ............................................................................................................ 1
4 2076255 Tube Assy ........................................................................................................... 1
5 1473897 Fitting .................................................................................................................. 1
5 265731 O-Ring ............................................................................................................ 1
5 16484 O-Ring ............................................................................................................ 1
6 1582511 Clip ...................................................................................................................... 2
7 1598091 Bracket ................................................................................................................ 1
8 2076256 Hose Assy (High Temp) ...................................................................................... 1
9 b 2085742 Tube .................................................................................................................... 1
9 a 2085745 Tube .................................................................................................................... 1
10 b 2085744 Tube .................................................................................................................... 1
10 a 2085746 Tube .................................................................................................................... 1
11 1522424 Fitting .................................................................................................................. 1
11 1527813 O-Ring ............................................................................................................ 3
12 b 2085743 Tube .................................................................................................................... 1
12 a 2085748 Tube .................................................................................................................... 1
13 b 2085741 Tube .................................................................................................................... 1
13 a 2085747 Tube .................................................................................................................... 1
14 1522425 Fitting .................................................................................................................. 1
14 265787 O-Ring ............................................................................................................ 3
15 17758 Fitting .................................................................................................................. 4
15 16486 O-Ring ............................................................................................................ 1
16 1502009 Hose Clamp ........................................................................................................ 4
17 2089061 Hose ................................................................................................................... 1
18 17221 Fitting .................................................................................................................. 2
18 16483 O-Ring ............................................................................................................ 1
19 1569616 Hose Clamp ........................................................................................................ 2
20 2073768 Hose Assy ........................................................................................................... 1
21 1486737 Fitting .................................................................................................................. 1
21 1527813 O-Ring ............................................................................................................ 1
21 16481 O-Ring ............................................................................................................ 1
22 1550965 Hose (High Temp) .............................................................................................. 1
23 2089062 Hose ................................................................................................................... 1
24 1399323 Pad ..................................................................................................................... 1
25 1527879 Capscrew ............................................................................................................ 1
26 1396346 Clamp ................................................................................................................. 1

FOOTNOTES:
a S100-120FT b S80FT

©2011 HYSTER COMPANY See Service Manual 8-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BRAKE COOLING SYSTEM (FIGURE 8-10)

SINGLE AND DUAL PEDAL — WET BRAKE (S/N G004V01515D →)

8-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BRAKE COOLING SYSTEM

SINGLE AND DUAL PEDAL – WET BRAKE (S/N G004V01515D →)

ITEM PART NO. DESCRIPTION QTY

1 1640573 Fitting ................................................................................................................. 2
2 1569616 Hose Clamp ....................................................................................................... 2
3 1487061 Fitting ................................................................................................................. 2
3 16484 O-Ring ........................................................................................................... 1
3 265787 O-Ring ............................................................................................................ 1
4 1502053 Clamp (Swivel) .................................................................................................. 2
5 1543698 Clamp (Swivel) .................................................................................................. 2
6 2091015 Hose Assy ......................................................................................................... 1
7 a 164289 Hose ................................................................................................................... 1
7 c 112385 Hose ................................................................................................................... 1
8 222501 Fitting ................................................................................................................. 1
8 16483 O-Ring ........................................................................................................... 1
9 1516199 Fitting ................................................................................................................. 1
9 16483 O-Ring ........................................................................................................... 1
9 265787 O-Ring ............................................................................................................ 1
10 1598091 Bracket ............................................................................................................... 1
11 1473897 Fitting ................................................................................................................. 1
11 265731 O-Ring ............................................................................................................ 1
11 16484 O-Ring ........................................................................................................... 1
12 2076255 Tube Assy .......................................................................................................... 1
13 1582511 Clip ..................................................................................................................... 1
14 2076256 Hose Assy (High Temp) ................................................................................... 1
15 1522425 Fitting ................................................................................................................. 1
15 265787 O-Ring ............................................................................................................ 3
16 2094158 Tube (S80FT) ..................................................................................................... 1
16 2094156 Tube (S100-120FT) ............................................................................................ 1
17 b 77186 Fitting .................................................................................................................. 1
17 16487 O-Ring ................................................................................................................ 1
17 16487 O-Ring ........................................................................................................... 1
17 16484 O-Ring ........................................................................................................... 1
18 1486737 Fitting ................................................................................................................. 1
18 1527813 O-Ring ............................................................................................................ 1
18 16481 O-Ring ........................................................................................................... 1
19 2094153 Tube (S80FT) ..................................................................................................... 1
19 2094154 Tube (S100-120FT) ............................................................................................ 1
20 1522424 Fitting ................................................................................................................. 1
20 1527813 O-Ring ............................................................................................................ 3
21 2094155 Tube ................................................................................................................... 1
22 2073768 Hose Assy ......................................................................................................... 1
23 2094157 Tube ................................................................................................................... 1
24 2091513 Block .................................................................................................................. 1
25 17758 Fitting ................................................................................................................. 2
25 16486 O-Ring ........................................................................................................... 1
26 1502009 Hose Clamp ....................................................................................................... 4
27 2090184 Hose (LH) ........................................................................................................... 1
28 1637397 Fitting ................................................................................................................. 1
29 2090185 Hose (RH) .......................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 8-29

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a → 9/2007
b → 9/2008
c 9/2007 →

8-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

9 HYDRAULIC SYSTEM
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 9
HYDRAULIC SYSTEM

DESCRIPTION PAGE

AUXILIARY HOSES ........................................................................................................................................ 9-70

ELECTRONIC CONTROL VALVE
AUXILIARY ONE SECTION - THREE, FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ............... 9-52
AUXILIARY ONE SECTION - THREE, FOUR AND FIVE FUNCTION (S/N G004V04329G →) ............... 9-54
AUXILIARY TWO SECTION - FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ............................. 9-56
AUXILIARY TWO SECTION - FOUR AND FIVE FUNCTION (S/N G004V04329G →) ............................. 9-58
LIFT AND LOWER - THREE, FOUR, AND FIVE FUNCTION .................................................................... 9-46
OUTLET SECTION - THREE, FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ............................ 9-60
OUTLET SECTION - THREE, FOUR AND FIVE FUNCTION (S/N G004V04329G →) ............................ 9-62
TILT SECTION - THREE, FOUR, AND FIVE FUNCTION .......................................................................... 9-50
ELECTRONIC CONTROL VALVE ASSEMBLY
FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ............................................................................. 9-42
FOUR AND FIVE FUNCTION (S/N G004V04329G →) ............................................................................. 9-44
THREE FUNCTION (→ S/N G004V04328G) ............................................................................................. 9-38
THREE FUNCTION (S/N G004V04329G →) ............................................................................................. 9-40
ELECTRONIC HYDRAULIC POPPET VALVE
THREE, FOUR AND FIVE FUNCTION ....................................................................................................... 9-48
GEAR PUMP
→ 12/2009 .................................................................................................................................................. 9-10
1/2010 → .................................................................................................................................................... 9-12
HAND LEVERS
FOUR FUNCTION - WITH DETENTED LEVERS ....................................................................................... 9-18
FOUR FUNCTION - WITHOUT DETENTED LEVERS ............................................................................... 9-20
THREE FUNCTION - WITH DETENTED LEVERS ..................................................................................... 9-14
THREE FUNCTION - WITHOUT DETENTED LEVERS ............................................................................. 9-16
HOIST HOSE AND ATTACHING PARTS ....................................................................................................... 9-73
HYDRAULIC FILTER ...................................................................................................................................... 9-6
HYDRAULIC OIL COOLER ............................................................................................................................. 9-8
HYDRAULIC SUPPLY AND RETURN ............................................................................................................ 9-2
MANUAL CONTROL VALVE
AUXILIARY ONE AND TWO SECTION - THREE AND FOUR
FUNCTION (→ S/N G004V02934E (THREE FUNCTION)) (→ S/N G004V02942E (FOUR FUNCTION))
.................................................................................................................................................................... 9-32
AUXILIARY ONE AND TWO SECTION - THREE AND FOUR
FUNCTION (S/N G004V02935E → (THREE FUNCTION))
(S/N G004V02943E → (FOUR FUNCTION)(FOUR FUNCTION)) ............................................................ 9-34
LIFT AND TILT - THREE AND FOUR FUNCTION (→ S/N G004V02934E (THREE FUNCTION))
(→ S/N G004V02942E (FOUR FUNCTION)) ............................................................................................. 9-26
LIFT AND TILT - THREE AND FOUR FUNCTION (S/N G004V02935E → (THREE FUNCTION))
(S/N G004V02943E → (FOUR FUNCTION)) ............................................................................................. 9-28
LIFT AND TILT - THREE AND FOUR FUNCTION (S/N G004V04302G →) ............................................. 9-30
OUTLET SECTION - THREE, FOUR, AND FIVE FUNCTION ................................................................... 9-36
MANUAL CONTROL VALVE ASSEMBLY
THREE AND FOUR FUNCTION ................................................................................................................. 9-22
MANUAL CONTROL VALVE LOCKOUT GROUP .......................................................................................... 9-24
TILT CYLINDER .............................................................................................................................................. 9-66
TILT CYLINDER INSTALLATION ................................................................................................................... 9-64
TILT HOSES .................................................................................................................................................... 9-68
VENT LINE GROUP ........................................................................................................................................ 9-72
©2011 HYSTER COMPANY See Service Manual 9-1
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HYDRAULIC SUPPLY AND RETURN (FIGURE 9-1)

9-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HYDRAULIC SUPPLY AND RETURN

ITEM PART NO. DESCRIPTION QTY
1 i 1567693 Hydraulic Filter (FFigure 9-2)............................................................................. 1
1 l 4001029 Hydraulic Filter (FFigure 9-2)............................................................................. 1
2 f 2068337 Pressure Switch .................................................................................................. 1
3 2060809 Dipstick .............................................................................................................. 1
3 1580682 O-Ring ........................................................................................................... 1
4 1570264 Fitting ................................................................................................................. 1
4 16484 O-Ring ........................................................................................................... 1
5 1367369 Hose ................................................................................................................... 1
6 1502007 Hose Clamp ....................................................................................................... 2
7 1582161 Breather ............................................................................................................. 1
7 16486 O-Ring ........................................................................................................... 1
8 2081865 Surge Tank ........................................................................................................ 1
9 296016 Capscrew ........................................................................................................... 2
10 1617083 Spacer ................................................................................................................ 1
11 1502543 Nut (Flange) ....................................................................................................... 2
12 1624905 Strainer .............................................................................................................. 1
12 18909 O-Ring ........................................................................................................... 1
13 1527983 Hose Clamp ........................................................................................................ 4
14 2079736 Hose ................................................................................................................... 1
15 1549449 Hose Clamp ........................................................................................................ 2
16 h 2079731 Tube .................................................................................................................... 1
16 k 2098326 Tube ................................................................................................................... 1
17 1527879 Capscrew ........................................................................................................... 3
18 1473888 Fitting ................................................................................................................. 1
18 280154 O-Ring ........................................................................................................... 1
18 16486 O-Ring ........................................................................................................... 1
19 dg 2104449 Gear Pump (32.5 cc) .......................................................................................... 1
19 dj 4602292 Gear Pump (32.5 cc) (FFigure 9-5)................................................................... 1
19 beg 2082654 Gear Pump (41.3 cc) .......................................................................................... 1
19 bej 4602289 Gear Pump (41.3 cc) (FFigure 9-5)................................................................... 1
19 eg 2077588 Gear Pump (46.5 cc) .......................................................................................... 1
19 j 4602290 Gear Pump (46.5 cc) (FFigure 9-5)................................................................... 1
19 cg 2086562 Gear Pump (51.6 cc) .......................................................................................... 1
19 cj 4602291 Gear Pump (51.6 cc) (FFigure 9-5)................................................................. 1
20 264159 Adhesive ............................................................................................................ AR
21 1566890 Adapter .............................................................................................................. 1
21 a 16983 O-Ring ................................................................................................................ 1
22 2079735 Hose ................................................................................................................... 1
23 1564515 Capscrew ........................................................................................................... 2
24 2084750
2088916 Hose Assy ......................................................................................................... 1
25 1473898 Fitting ................................................................................................................. 1
25 280154 O-Ring ........................................................................................................... 1
25 16486 O-Ring ........................................................................................................... 1
26 369804 Clamp ................................................................................................................. 2
27 2070609 Hose (3 and 4 Function) ..................................................................................... 1
27 2072188 Hose (5 Function) ............................................................................................... 1
28 213619 Fitting ................................................................................................................. 1
28 16983 O-Ring ........................................................................................................... 1
29 1502543 Nut (Flange) ....................................................................................................... 4
30 i 132861 Capscrew ............................................................................................................ 4

©2011 HYSTER COMPANY See Service Manual 9-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HYDRAULIC SUPPLY AND RETURN

ITEM PART NO. DESCRIPTION QTY
31 i 1639704 Seal ..................................................................................................................... 4
32 i 1637158 Retainer .............................................................................................................. 4
33 i 1624189 Retainer .............................................................................................................. 4
a 1528481 Plug (With O-Ring) (Tank Drain) ...................................................................... 1

FOOTNOTES:
a Not Illustrated g → PENDING PER ECN 106196
b S100-120FT Low Displacement for Paper Industry h → S/N G004V02834E
c S100-120FT Standard Displacement i → S/N G004V04544G
d S80-90FT Low Displacement for Paper Industry j PENDING PER ECN 106196 →
e S80-90FT Standard Displacement k S/N G004V02835E →
f With Electronic Monitoring Package l S/N G004V04545G →

9-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 9-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HYDRAULIC FILTER (FIGURE 9-2)

9-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HYDRAULIC FILTER
ITEM PART NO. DESCRIPTION QTY
b 1567693 Hydraulic Filter Assembly ................................................................................... 1
c 4001029 Hydraulic Filter Assembly ................................................................................... 1
1 b 1615173 Cap Assembly ................................................................................................ 1
1 c 1708697 Cap Assembly ................................................................................................ 1
1 ..... O-Ring ........................................................................................................ 1
1 ..... Spring ......................................................................................................... 1
2 b 1624654 Hydraulic Filter ............................................................................................... 1
2 c 4000998 Filter ............................................................................................................... 1
2 ..... O-Ring ........................................................................................................ 1
3 b 1624657 Bowl Assembly ............................................................................................... 1
3 c. . . . . Bowl Assembly ............................................................................................... 1
3 ..... O-Ring ........................................................................................................ 1
4 b 1627364 Head ............................................................................................................... 1
4 ..... Quad Ring ...................................................................................................... 1
4 14591 Plug ................................................................................................................ 1
4 16481 O-Ring ............................................................................................................ 1
5 1502543 Nut (Flange) ........................................................................................................ 4
6 a 2068337 Pressure Switch .................................................................................................. 1
b 1624663 Kit-O-Ring (Includes Items 1-4) .......................................................................... 1
1708691 Kit-O-Ring (Includes Items 1-4) .......................................................................... 1

FOOTNOTES:
a With Electronic Monitoring Package c S/N G004V04545G →
b → S/N G004V04544G

©2011 HYSTER COMPANY See Service Manual 9-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HYDRAULIC OIL COOLER (FIGURE 9-3)

ITEM PART NO. DESCRIPTION QTY

1636229 Oil Cooler ............................................................................................................ 1
1 ..... Heat Exchanger .............................................................................................. 1
2 1688059 Switch (Temperature) ..................................................................................... 1
3 ..... Plug ................................................................................................................ 1
4 1500970 Lockwasher .................................................................................................... 4
5 1688061 Capscrew ....................................................................................................... 4
6 1607369 Fan ................................................................................................................. 1
..... Clamp ............................................................................................................. 1

9-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 9-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

GEAR PUMP (FIGURE 9-4)

(→ 12/2009)

9-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

GEAR PUMP
(→ 12/2009)

ITEM PART NO. DESCRIPTION QTY

acfg 2082654 Gear Pump (41.3 cc) .......................................................................................... 1
bi 2086562 Gear Pump (51.6 cc) .......................................................................................... 1
ej 2077588 Gear Pump (46.5 cc) .......................................................................................... 1
dh 2104449 Gear Pump (32.5 cc) .......................................................................................... 1
1 1624864 Bolt (41.3 cc) .................................................................................................. 4
1 1636046 Bolt (51.6 cc) .................................................................................................. 4
1 2089776 Bolt (46.5 cc) .................................................................................................. 4
1 1695082 Bolt (32.5 cc) .................................................................................................. 4
2 1624865 Washer ........................................................................................................... 4
3 1624853 Cover .............................................................................................................. 1
4 1624862 Plate (Seal) ..................................................................................................... 2
5 1624863 Back-Up Ring ................................................................................................. 2
6 1624861 Pressure Plate ................................................................................................ 2
7 ..... Gear Plate ...................................................................................................... 1
8 1624869 Gear Set (41.3 cc) .......................................................................................... 1
8 1624870 Gear Set (51.6 cc) .......................................................................................... 1
8 1624992 Gear Set (46.5 cc) .......................................................................................... 1
8 1695078 Gear Set (32.5 cc) .......................................................................................... 1
8 ..... Drive Gear .................................................................................................. 1
8 ..... Driven Gear ................................................................................................ 1
9 1624856 Flange ............................................................................................................ 1
10 1624866 Oil Seal ........................................................................................................... 1
11 1624867 Snap Ring ....................................................................................................... 1
1624868 Kit-Seal (Includes Items 4-5, 10-11) ................................................................... 1

FOOTNOTES:
a 100-120 Low Displacement for Paper Industry, f 80-90 Standard Displacement, Gasoline, Diesel
Gasoline and LPG and LPG
b 100-120 Standard Displacement, Gasoline, Diesel g → S/N G004V04601G
and LPG h → S/N G004V04673H
c 80-120 Low Displacement for Paper Industry, i → S/N G004V04694H
Diesel j → S/N G004V04754H
d 80-90 Low Displacement for Paper Industry,
Gasoline and LPG
e 80-90 Standard Displacement, Diesel

©2011 HYSTER COMPANY See Service Manual 9-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

GEAR PUMP (FIGURE 9-5)

(1/2010 →)

9-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

GEAR PUMP
(1/2010 →)

ITEM PART NO. DESCRIPTION QTY

acfg 4602289 Gear Pump (41.3 cc) .......................................................................................... 1
bi 4602291 Gear Pump (51.6 cc) ......................................................................................... 1
ej 4602290 Gear Pump (46.5 cc) .......................................................................................... 1
dh 4602292 Gear Pump (32.5 cc) .......................................................................................... 1
1 4009235 Screw (Flange Head) (41.3 cc) ...................................................................... 1
1 4009237 Screw (Flange Head) (51.6 cc) ..................................................................... 1
1 4009236 Screw (Flange Head) (46.5 cc) ...................................................................... 1
1 4009234 Screw (Flange Head) (32.5 cc) ...................................................................... 1
2 1624865 Washer ........................................................................................................... 4
3 1624853 Cover ............................................................................................................. 1
4 1624862 Plate (Seal) .................................................................................................... 2
5 1624863 Back-Up Ring ................................................................................................ 2
6 1624861 Pressure Plate .............................................................................................. 2
7 ..... Gear Plate ...................................................................................................... 1
8 1624869 Gear Set (41.3 cc) .......................................................................................... 1
8 1624870 Gear Set (51.6 cc) ......................................................................................... 1
8 1624992 Gear Set (46.5 cc) .......................................................................................... 1
8 1695078 Gear Set (32.5 cc) .......................................................................................... 1
8 ..... Drive Gear ................................................................................................. 1
8 ..... Driven Gear ............................................................................................... 1
9 4009240 Flange ............................................................................................................ 1
10 1624866 Oil Seal .......................................................................................................... 1
11 1624867 Snap Ring ...................................................................................................... 1
1624868 Kit-Seal (Includes Items 4-5, 10-11) ................................................................... 1

FOOTNOTES:
a 100-120 Low Displacement for Paper Industry, f 80-90 Standard Displacement, Gasoline and LPG
Gasoline and LPG g S/N G004V04602G →
b 100-120 Standard Displacement, Gasoline, LPG h S/N G004V04674H →
and Diesel i S/N G004V04695H →
c 80-120 Low Displacement for Paper Industry, j S/N G004V04754H →
Diesel
d 80-90 Low Displacement for Paper Industry,
Gasoline and LPG
e 80-90 Standard Displacement, Diesel

©2011 HYSTER COMPANY See Service Manual 9-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HAND LEVERS (FIGURE 9-6)

THREE FUNCTION — WITH DETENTED LEVERS

9-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HAND LEVERS
THREE FUNCTION – WITH DETENTED LEVERS

ITEM PART NO. DESCRIPTION QTY

1 b 1578454 Bracket ................................................................................................................ 1
1 c 1670194 Bracket ................................................................................................................ 1
2 1527879 Capscrew ............................................................................................................ 3
3 b 230882 Locknut ............................................................................................................... 1
3 c 316834 Nut ...................................................................................................................... 1
4 b 197067 Washer ............................................................................................................... 2
4 c 320156 Washer ............................................................................................................... 1
5 b 1528339 Spacer ................................................................................................................ 1
5 c 1670677 Plate .................................................................................................................... 1
6 b 18094 Capscrew ............................................................................................................ 1
6 c 1527878 Capscrew ............................................................................................................ 1
7 1583611 Capscrew ............................................................................................................ 2
8 175861 Spring ................................................................................................................. 1
9 302428 Roll Pin ............................................................................................................... 1
10 1542546 Lever ................................................................................................................... 2
11 1564747 Bushing ............................................................................................................... 10
12 306113 Pin (Selector) ...................................................................................................... 1
13 320161 Washer ............................................................................................................... 2
14 b 1528328 Shaft ................................................................................................................... 1
14 c 1670195 Shaft (Pivot) (Alternate Part) ............................................................................... 1
15 1517361 Locking Ring Cotter Pin ...................................................................................... 6
16 309109 Pin ....................................................................................................................... 6
17 b 1517394 Link ..................................................................................................................... 3
17 c 1662420 Link ..................................................................................................................... 3
18 b 2083706 Lever (Auxiliary One and Two) ........................................................................... 1
18 c 2099398 Lever (Auxiliary One and Two) ........................................................................... 1
19 b 2083702 Lever (Tilt) ........................................................................................................... 1
19 c 2099394 Lever (Tilt) ........................................................................................................... 1
20 b 2083701 Lever (Lift) ........................................................................................................... 1
20 c 2099393 Lever (Lift) ........................................................................................................... 1
21 1517395 Knob ................................................................................................................... 3
22 1586627 Capscrew ............................................................................................................ 3
23 1346752 Washer ............................................................................................................... 3
24 2063991 Isolator ................................................................................................................ 3
..... Lockout Group .................................................................................................... 1
a. . . . . Hydraulic Control Valve (FFigure 9-10)............................................................. 1

FOOTNOTES:
a → PENDING PER ECN 104512 c S/N G004V03264F → INC. 03240-03242,
b → S/N G004V03263F 03244-03247

©2011 HYSTER COMPANY See Service Manual 9-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HAND LEVERS (FIGURE 9-7)

THREE FUNCTION — WITHOUT DETENTED LEVERS

9-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HAND LEVERS
THREE FUNCTION – WITHOUT DETENTED LEVERS

ITEM PART NO. DESCRIPTION QTY

1 b 1578453 Bracket ................................................................................................................ 1
1 c 1656383 Bracket ................................................................................................................ 1
1 1665746 Bracket ................................................................................................................ 1
2 1527879 Capscrew ............................................................................................................ 3
3 1583611 Capscrew ............................................................................................................ 2
4 1528327 Shaft ................................................................................................................... 1
4 1670292 Shaft ................................................................................................................... 1
5 1564747 Bushing ............................................................................................................... 6
6 2083701 Lever (Lift) ........................................................................................................... 1
6 2099393 Lever (Lift) ........................................................................................................... 1
7 2083702 Lever (Tilt) ........................................................................................................... 1
7 2099394 Lever (Tilt) ........................................................................................................... 1
8 2083703 Lever (Auxiliary One) .......................................................................................... 1
8 2099395 Lever (Auxiliary One) .......................................................................................... 1
9 1517395 Knob ................................................................................................................... 3
10 ab 1517394 Link ..................................................................................................................... 3
10 c 1643709 Link ..................................................................................................................... 3
10 1662420 Link (Alternate Part) ............................................................................................ 3
11 309109 Pin ....................................................................................................................... 6
12 1517361 Locking Ring Cotter Pin ...................................................................................... 6
13 1586627 Capscrew ............................................................................................................ 3
14 1346752 Washer ............................................................................................................... 3
15 2063991 Isolator ................................................................................................................ 3
..... Lockout Group (FFigure 9-10)........................................................................... 1
..... Hydraulic Control Valve (FFigure 9-10)............................................................. 1

FOOTNOTES:
a → PENDING PER ECN 104512 c S/N G004V02935E ↔ S/N G004V03263F EXC.
b → S/N G004V02934E 03240-03242, 03244-03247

©2011 HYSTER COMPANY See Service Manual 9-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HAND LEVERS (FIGURE 9-8)

FOUR FUNCTION — WITH DETENTED LEVERS

9-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HAND LEVERS
FOUR FUNCTION – WITH DETENTED LEVERS

ITEM PART NO. DESCRIPTION QTY

1 a 1619997 Bracket ................................................................................................................ 1
1 c 1656385 Bracket ................................................................................................................ 1
1 d 1665748 Bracket ................................................................................................................ 1
2 1527879 Capscrew ............................................................................................................ 4
3 b 230882 Locknut ............................................................................................................... 1
3 d 316834 Nut ...................................................................................................................... 1
4 b 197067 Washer ............................................................................................................... 2
4 d 320156 Washer ............................................................................................................... 1
5 b 1528339 Spacer ................................................................................................................ 1
5 d 1670677 Plate .................................................................................................................... 1
6 b 18094 Capscrew ............................................................................................................ 1
6 d 1527878 Capscrew ............................................................................................................ 1
7 1583611 Capscrew ............................................................................................................ 2
8 175861 Spring ................................................................................................................. 1
9 302428 Roll Pin ............................................................................................................... 1
10 1542546 Lever ................................................................................................................... 2
11 1564747 Bushing ............................................................................................................... 12
12 306113 Pin (Selector) ...................................................................................................... 1
13 b 1528329 Shaft ................................................................................................................... 1
13 d 1670196 Shaft ................................................................................................................... 1
14 320161 Washer ............................................................................................................... 2
15 a 1517394 Link ..................................................................................................................... 4
15 d 1643709 Link ..................................................................................................................... 4
15 d 1662420 Link ..................................................................................................................... 4
16 1517361 Locking Ring Cotter Pin ...................................................................................... 8
17 309109 Pin ....................................................................................................................... 8
18 b 2083705 Lever (Auxiliary Two and Three) ......................................................................... 1
18 d 2099397 Lever (Auxiliary Two and Three) ......................................................................... 1
19 b 2083703 Lever (Auxiliary One) .......................................................................................... 1
19 d 2099395 Lever (Auxiliary One) .......................................................................................... 1
20 b 2083702 Lever (Tilt) ........................................................................................................... 1
20 d 2099394 Lever (Tilt) ........................................................................................................... 1
21 b 2083701 Lever (Lift) ........................................................................................................... 1
21 d 2099393 Lever (Lift) ........................................................................................................... 1
22 1517395 Knob ................................................................................................................... 4
22 2070655 Lens (Blank) ........................................................................................................ 1
23 1586627 Capscrew ............................................................................................................ 3
24 1346752 Washer ............................................................................................................... 3
25 2063991 Isolator ................................................................................................................ 3
..... Hydraulic Control Valve (FFigure 9-10)............................................................. 1

FOOTNOTES:
a → S/N G004V02942E c S/N G004V02943E ↔ S/N G004V03263F
b → S/N G004V03263F d S/N G004V03264F → INC. 03240-03242,
03244-03247

©2011 HYSTER COMPANY See Service Manual 9-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HAND LEVERS (FIGURE 9-9)

FOUR FUNCTION — WITHOUT DETENTED LEVERS

9-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HAND LEVERS
FOUR FUNCTION – WITHOUT DETENTED LEVERS

ITEM PART NO. DESCRIPTION QTY

1 a 1578454 Bracket ................................................................................................................ 1
1 c 1665747 Bracket ................................................................................................................ 1
2 1527879 Capscrew ............................................................................................................ 3
3 1583611 Capscrew ............................................................................................................ 2
4 a 1528328 Shaft ................................................................................................................... 1
4 c 1670293 Shaft ................................................................................................................... 1
5 1564747 Bushing ............................................................................................................... 8
6 a 2083704 Lever (Auxiliary Two) .......................................................................................... 1
6 b 2099396 Lever (Auxiliary Two) .......................................................................................... 1
7 a 2083703 Lever (Auxiliary One) .......................................................................................... 1
7 c 2099395 Lever (Auxiliary One) .......................................................................................... 1
8 a 2083702 Lever (Tilt) ........................................................................................................... 1
8 c 2099394 Lever (Tilt) ........................................................................................................... 1
9 a 2083701 Lever (Lift) ........................................................................................................... 1
9 c 2099393 Lever (Lift) ........................................................................................................... 1
10 1517395 Knob ................................................................................................................... 4
10 2070655 Lens (Blank) ........................................................................................................ 1
11 a 1517394 Link ..................................................................................................................... 4
11 c 1662420 Link ..................................................................................................................... 4
12 309109 Pin ....................................................................................................................... 8
13 1517361 Locking Ring Cotter Pin ...................................................................................... 8
14 1586627 Capscrew ............................................................................................................ 3
15 1346752 Washer ............................................................................................................... 3
16 2063991 Isolator ................................................................................................................ 3
..... Hydraulic Control Valve (FFigure 9-10)............................................................. 1

FOOTNOTES:
a → S/N G004V03263F c S/N G004V03264F → INC. 03240-03242,
b S/N G004V03264F → 03244-03247

©2011 HYSTER COMPANY See Service Manual 9-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MANUAL CONTROL VALVE ASSEMBLY (FIGURE 9-10)

THREE AND FOUR FUNCTION

9-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MANUAL CONTROL VALVE ASSEMBLY

THREE AND FOUR FUNCTION
KEY:
A: Three Function
B: Four Function
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
b 2078046 Hydraulic Control Valve .............................................................................. 1 ..
d 2095092 Hydraulic Control Valve .............................................................................. 1 ..
g 2105887 Hydraulic Control Valve .............................................................................. 1 ..
c 2078048 Hydraulic Control Valve .............................................................................. .. 1
e 2095094 Hydraulic Control Valve .............................................................................. .. 1
g 2105889 Hydraulic Control Valve ........................................................................... .. 1
1 b 2078045 Hydraulic Control Valve ......................................................................... 1 ..
1 1580146 Kit-Seal (Three Function) .................................................................. 1 ..
1 d 2095096 Hydraulic Control Valve ......................................................................... 1 ..
1 g 2105891 Hydraulic Control Valve ......................................................................... 1 ..
1 1670434 Kit-Seal (Three Function) .................................................................. 1 ..
1 c 2078047 Hydraulic Control Valve ......................................................................... .. 1
1 1580148 Kit-Seal (Four Function) .................................................................... .. 1
1 e 2095097 Hydraulic Control Valve ......................................................................... .. 1
1 g 2105892 Hydraulic Control Valve ...................................................................... .. 1
1 1670054 Kit-Seal (Four Function) ................................................................. .. 1
2 1559973 Relief Valve (3100 PSI) (Main Relief) .............................................. 1 1
2 1580097 Kit-Seal ............................................................................................. 1 1
3 1578707 Relief Valve (2250 PSI) (Secondary) .............................................. 1 1
3 1580131 Kit-Seal ............................................................................................. 1 1
4 bc 1578815 Valve Section (Lift and Tilt) (FFigure 9-12)...................................... 1 1
4 de 1670432 Valve Section (Lift and Tilt) (FFigure 9-13)...................................... 1 1
4 g 1702466 Valve Section (Lift And Tilt) (FFigure 9-14).................................. 1 1
5 bc 1628747 Valve Section (FFigure 9-15)........................................................... 1 1
5 hf 1670431 Valve Section (FFigure 9-16)......................................................... 1 1
6 bc 1628748 Valve Section (FFigure 9-15)........................................................... .. 1
6 hf 1670533 Valve Section (FFigure 9-16)......................................................... .. 1
7 1578746 Valve Section (FFigure 9-17)......................................................... 1 1
8 a 2063121 Steering Control Unit ............................................................................. 1 1
8 i 2102565 Steering Control Unit ........................................................................... 1 1

FOOTNOTES:
a → 9/2007 f S/N G004V02943E →
b → S/N G004V02934E g S/N G004V04302G →
c → S/N G004V02942E h S/N G004V02935E →
d S/N G004V02935E ↔ S/N G004V04301G i 9/2007 →
e S/N G004V02943E ↔ S/N G004V04301G

©2011 HYSTER COMPANY See Service Manual 9-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MANUAL CONTROL VALVE LOCKOUT GROUP (FIGURE 9-11)

9-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MANUAL CONTROL VALVE LOCKOUT GROUP

KEY:
A: 3 Function
B: 4 Function
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1683529 Solenoid Assembly (Double Function) .................................................. 1 2
2 1683621 Solenoid Assembly (Single Function) ........................................................ 1 ..
3 18748 Capscrew .................................................................................................. 4 4
4 1670413 Needle Roller ............................................................................................ 3 4
5 ..... Manual Control Valve (FFigure 9-10)..................................................... 1 1

©2011 HYSTER COMPANY See Service Manual 9-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MANUAL CONTROL VALVE (FIGURE 9-12)

LIFT AND TILT — THREE AND FOUR FUNCTION (→ S/N G004V02934E (THREE FUNCTION))
(→ S/N G004V02942E (FOUR FUNCTION))

9-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MANUAL CONTROL VALVE

LIFT AND TILT – THREE AND FOUR FUNCTION (→ S/N G004V02934E (THREE FUNCTION))
(→ S/N G004V02942E (FOUR FUNCTION))

ITEM PART NO. DESCRIPTION QTY

1578815 Valve Section (Lift and Tilt) ................................................................................. 1
1 1578940 Plug ................................................................................................................ 1
2 1578713 Plug ................................................................................................................ 2
3 77442 Spring ............................................................................................................. 3
4 1578943 Poppet ............................................................................................................ 1
5 77443 Poppet ............................................................................................................ 2
6 16706 Screw ............................................................................................................. 4
7 188515 Plate ............................................................................................................... 2
8 1670445 Kit-Seal (Lift and Tilt) ...................................................................................... 1
9 ..... Seal Plate ....................................................................................................... 2
10 320289 Spring Seat ..................................................................................................... 2
11 188517 Spring ............................................................................................................. 2
12 1581861 Piston ............................................................................................................. 1
13 341462 Spring ............................................................................................................. 1
14 386015 Spool End ....................................................................................................... 1
14 320291 Spool End ................................................................................................... 1
14 16480 O-Ring ........................................................................................................ 1
15 1560681 Cap ................................................................................................................. 2
16 1628746 Capscrew ....................................................................................................... 4
17 1581859 Spool End ....................................................................................................... 1
18 1578747 Relief Valve (3100 PSI) (Main Relief) ............................................................. 1
19 ..... Plug ............................................................................................................ 1
20 ..... Screw ......................................................................................................... 1
21 ..... Nut .............................................................................................................. 1
22 ..... Washer ....................................................................................................... 1
23 ..... Poppet ........................................................................................................ 1
24 1580097 Kit-Seal ....................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 9-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MANUAL CONTROL VALVE (FIGURE 9-13)

LIFT AND TILT — THREE AND FOUR FUNCTION (S/N G004V02935E → (THREE FUNCTION))
(S/N G004V02943E → (FOUR FUNCTION))

9-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MANUAL CONTROL VALVE

LIFT AND TILT – THREE AND FOUR FUNCTION (S/N G004V02935E → (THREE FUNCTION))
(S/N G004V02943E → (FOUR FUNCTION))
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1670432 Valve Section (Lift and Tilt) ........................................................................ 1 1
2 1578707 Relief Valve (2250 PSI) (Secondary) ..................................................... 1 1
2 1559973 Relief Valve (3100 PSI) (Main Relief) .................................................... 1 1
2 1580694 Plug ................................................................................................... 1 1
2 1580697 Screw ................................................................................................ 1 1
2 1580698 Nut ..................................................................................................... 1 1
2 1580695 Washer .............................................................................................. 1 1
2 1580696 Poppet ............................................................................................... 1 1
3 1580097 Kit-Seal .............................................................................................. 1 1
4 1569602 Plug ........................................................................................................ 1 1
5 1670445 Kit-Seal (Lift and Tilt) ............................................................................. 1 1
6 ..... Seal Plate .............................................................................................. 2 2
7 320289 Spring Seat ............................................................................................ 4 4
8 188517 Spring .................................................................................................... 2 2
9 1581859 Spool End .............................................................................................. 1 1
10 1560681 Cap ........................................................................................................ 2 2
11 1578705 Capscrew ............................................................................................... 4 4
12 386015 Spool End .............................................................................................. 1 1
12 320291 Spool End .......................................................................................... 1 1
12 16480 O-Ring ............................................................................................... 1 1
13 341462 Spring .................................................................................................... 1 1
14 1581861 Piston ..................................................................................................... 1 1
15 1578713 Plug ........................................................................................................ 1 1
16 77442 Spring .................................................................................................... 3 3
17 77443 Poppet ................................................................................................... 2 2
18 188515 Plate ....................................................................................................... 2 2
19 16706 Screw ..................................................................................................... 4 4
20 1578943 Poppet ................................................................................................... 1 1
21 1670522 Kit-Valve (Manual Lower Assembly) ...................................................... 1 1
22 1578940 Plug ........................................................................................................ 1 1
1670054 Kit-Seal (Four Function) ......................................................................... .. 1
1670434 Kit-Seal (Three Function) ....................................................................... 1 ..

©2011 HYSTER COMPANY See Service Manual 9-29

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MANUAL CONTROL VALVE (FIGURE 9-14)

LIFT AND TILT — THREE AND FOUR FUNCTION (S/N G004V04302G →)

9-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MANUAL CONTROL VALVE

LIFT AND TILT – THREE AND FOUR FUNCTION (S/N G004V04302G →)

ITEM PART NO. DESCRIPTION QTY

1702466 Valve Section (Lift And Tilt) ............................................................................. 1
1 1578940 Plug ................................................................................................................ 1
2 1578713 Plug ................................................................................................................ 2
3 77442 Spring ............................................................................................................ 3
4 1578943 Poppet ........................................................................................................... 1
5 77443 Poppet ........................................................................................................... 2
6 16706 Screw ............................................................................................................. 4
7 188515 Plate ............................................................................................................... 2
8 1670445 Kit-Seal (Lift and Tilt) ................................................................................... 1
9 ..... Seal Plate ...................................................................................................... 2
10 320289 Spring Seat ................................................................................................... 4
11 188517 Spring ............................................................................................................ 2
12 1581861 Piston ............................................................................................................ 1
13 341462 Spring ............................................................................................................ 1
14 386015 Spool End ...................................................................................................... 1
14 320291 Spool End ................................................................................................. 1
14 16480 O-Ring ....................................................................................................... 1
15 1560681 Cap ................................................................................................................. 2
16 1628746 Capscrew ....................................................................................................... 4
17 1581859 Spool End ...................................................................................................... 1
18 1578747 Relief Valve (3100 PSI) (Main Relief) ............................................................. 1
19 1580694 Plug ........................................................................................................... 1
20 1580697 Screw ......................................................................................................... 1
21 1580698 Nut ............................................................................................................. 1
22 1580695 Washer ...................................................................................................... 1
23 1580696 Poppet ....................................................................................................... 1
24 1581858 Kit-Capscrew ............................................................................................ 1
25 1580097 Kit-Seal ...................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 9-31

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MANUAL CONTROL VALVE (FIGURE 9-15)

AUXILIARY ONE AND TWO SECTION — THREE AND FOUR FUNCTION
(→ S/N G004V02934E (THREE FUNCTION)) (→ S/N G004V02942E (FOUR FUNCTION))

9-32 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MANUAL CONTROL VALVE

AUXILIARY ONE AND TWO SECTION – THREE AND FOUR FUNCTION
(→ S/N G004V02934E (THREE FUNCTION)) (→ S/N G004V02942E (FOUR FUNCTION))
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1628747 Valve Section One or Two ......................................................................... 1 1
2 1628748 Valve Section One ..................................................................................... .. 1
3 16706 Screw ..................................................................................................... 2 2
4 188515 Plate ....................................................................................................... 1 1
5 1580147 Kit-Seal (Auxiliary Functions) ................................................................. 1 1
6 1578713 Plug ........................................................................................................ 1 1
6 77441 Plug ................................................................................................... 1 1
7 77442 Spring .................................................................................................... 1 1
8 77443 Poppet ................................................................................................... 1 1
9 ..... Seal Plate .............................................................................................. 1 1
10 320289 Spring Seat ............................................................................................ 1 1
11 188517 Spring .................................................................................................... 1 1
12 1581859 Spool End .............................................................................................. 1 1
13 1560681 Cap ........................................................................................................ 1 1
14 1628746 Capscrew ............................................................................................... 2 2

©2011 HYSTER COMPANY See Service Manual 9-33

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MANUAL CONTROL VALVE (FIGURE 9-16)

AUXILIARY ONE AND TWO SECTION — THREE AND FOUR FUNCTION
(S/N G004V02935E → (THREE FUNCTION)) (S/N G004V02943E → (FOUR FUNCTION)(FOUR FUNCTION))

9-34 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MANUAL CONTROL VALVE

AUXILIARY ONE AND TWO SECTION – THREE AND FOUR FUNCTION
(S/N G004V02935E → (THREE FUNCTION)) (S/N G004V02943E → (FOUR FUNCTION)(FOUR FUNCTION))
KEY:
A: Three Function
B: Four Function
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
1 1670431 Valve Section One or Two ....................................................................... 1 1
2 1670533 Valve Section One .................................................................................... .. 1
3 16706 Screw .................................................................................................... 2 2
4 188515 Plate ...................................................................................................... 1 1
5 1580147 Kit-Seal (Auxiliary Functions) ............................................................. 1 1
6 1578713 Plug ....................................................................................................... 1 1
6 77441 Plug ................................................................................................... 1 1
7 77442 Spring ................................................................................................... 1 1
8 77443 Poppet ................................................................................................... 1 1
9 ..... Seal Plate .............................................................................................. 1 1
10 320289 Spring Seat ........................................................................................... 1 1
11 188517 Spring ................................................................................................... 1 1
12 1581859 Spool End ............................................................................................. 1 1
13 1560681 Cap ........................................................................................................ 1 1
14 1578705 Capscrew .............................................................................................. 2 2
15 1578714 Plug ....................................................................................................... 1 1

©2011 HYSTER COMPANY See Service Manual 9-35

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MANUAL CONTROL VALVE (FIGURE 9-17)

OUTLET SECTION — THREE, FOUR, AND FIVE FUNCTION

ITEM PART NO. DESCRIPTION QTY

1 1578746 Valve Section .................................................................................................... 1
2 1580155 Kit-Tie Rod (Three Function) .............................................................................. 1
2 1580156 Kit-Tie Rod (Four Function) ............................................................................. 1
2 15055 Nut ................................................................................................................. 4
3 1578707 Relief Valve (2250 PSI) (Secondary) ................................................................ 1
4 ..... Nut ................................................................................................................. 1
5 ..... Screw ............................................................................................................. 1
6 ..... Washer .......................................................................................................... 1
7 ..... Poppet ........................................................................................................... 1
8 ..... Plug ................................................................................................................ 1
9 1580131 Kit-Seal .......................................................................................................... 1

9-36 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 9-37

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE ASSEMBLY (FIGURE 9-18)

THREE FUNCTION (→ S/N G004V04328G)

9-38 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE ASSEMBLY

THREE FUNCTION (→ S/N G004V04328G)

ITEM PART NO. DESCRIPTION QTY

cd 2078040 Hydraulic Control Valve ...................................................................................... 1
1 ab 2078039 Hydraulic Control Valve .................................................................................. 1
2 1629196 Valve Section (Inlet) (FFigure 9-22).......................................................... 1
3 1629197 Valve Section (Tilt) (FFigure 9-24)............................................................ 1
4 1629198 Valve Section (Auxiliary One) (FFigure 9-25)........................................... 1
5 1578704 Valve Section (Outlet) (FFigure 9-29)....................................................... 1
6 ..... Poppet Valve (Lower) (FFigure 9-23)....................................................... 1
7 ..... Poppet Valve (Lift) (FFigure 9-23)............................................................ 1
8 1578715 Kit-Tie Rod ................................................................................................. 1
9 e 2063121 Steering Control Unit (FFigure 7-3)............................................................... 1
9 f 2102565 Steering Control Unit (FFigure 7-3)............................................................... 1

FOOTNOTES:
a (Service 2078039 with 2103017 and plug d (Service 2078040 with kit 4000634)
1678166) e → 9/2007
b (Service 2078039 with kit 4000639) f 9/2007 →
c (Service 2078040 with 2103012 and plug
1678166)

©2011 HYSTER COMPANY See Service Manual 9-39

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE ASSEMBLY (FIGURE 9-19)

THREE FUNCTION (S/N G004V04329G →)

9-40 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE ASSEMBLY

THREE FUNCTION (S/N G004V04329G →)

ITEM PART NO. DESCRIPTION QTY

2103012 Hydraulic Control Valve ...................................................................................... 1
1 2103017 Hydraulic Control Valve .................................................................................. 1
2 1629196 Valve Section (Inlet) (FFigure 9-22).......................................................... 1
3 ..... Poppet Valve (FFigure 9-23)..................................................................... 1
4 1708317 Valve Section (Tilt) (FFigure 9-24)............................................................ 1
5 1708263 Valve Section (Aux. 1) (FFigure 9-26)...................................................... 1
6 1708262 Valve Section (Outlet) (FFigure 9-30)....................................................... 1
7 1581858 Kit-Capscrew .................................................................................................. 1
8 2102565 Steering Control Unit (FFigure 7-3)............................................................... 1
a 1678166 Plug ..................................................................................................................... 1
a 1578909 Kit-Seal ............................................................................................................... 1

FOOTNOTES:
a Not Illustrated

©2011 HYSTER COMPANY See Service Manual 9-41

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE ASSEMBLY (FIGURE 9-20)

FOUR AND FIVE FUNCTION (→ S/N G004V04328G)

9-42 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE ASSEMBLY

FOUR AND FIVE FUNCTION (→ S/N G004V04328G)
KEY:
A: Four Function
B: Five Function
QTY
ITEM PART NO. DESCRIPTION A B
2078042 Hydraulic Control Valve (Four Function) .................................................... 1 ..
2078044 Hydraulic Control Valve (Five Function) ..................................................... .. 1
1 2078041 Hydraulic Control Valve (Four Function) ................................................ 1 ..
1 2078043 Hydraulic Control Valve (Five Function) ................................................ .. 1
2 1629196 Valve Section (Inlet) (FFigure 9-22)................................................. 1 1
3 1629197 Valve Section (Tilt) (FFigure 9-24)................................................... 1 1
4 1629198 Valve Section (Auxiliary One) (FFigure 9-25).................................. 1 1
5 a 1633693 Valve Section (FFigure 9-27)........................................................... 1 2
6 1578704 Valve Section (Outlet) (FFigure 9-29).............................................. 1 1
7 ..... Poppet Valve (Lift) (FFigure 9-23).................................................... 1 1
8 ..... Poppet Valve (Lower) (FFigure 9-23)............................................... 1 1
9 b 2063121 Steering Control Unit (FFigure 7-3).................................................. 1 1
9 c 2102565 Steering Control Unit (FFigure 7-3).................................................. 1 1
10 1578715 Kit-Tie Rod ........................................................................................ 1 ..
10 1578750 Kit-Tie Rod ........................................................................................ .. 1

FOOTNOTES:
a Auxiliary Two or Three c 9/2007 →
b → 9/2007

©2011 HYSTER COMPANY See Service Manual 9-43

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE ASSEMBLY (FIGURE 9-21)

FOUR AND FIVE FUNCTION (S/N G004V04329G →)

9-44 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE ASSEMBLY

FOUR AND FIVE FUNCTION (S/N G004V04329G →)
KEY:
A: Four Function
B: Five Function
QTY
ITEM PART NO. DESCRIPTION A B
2103014 Hydraulic Control Valve (Four Function) .................................................... 1 ..
2103016 Hydraulic Control Valve (Five Function) ..................................................... .. 1
1 2103018 Hydraulic Control Valve (Four Function) ................................................ 1 ..
1 2103019 Hydraulic Control Valve (Five Function) ................................................ .. 1
2 1629196 Valve Section (Inlet) (FFigure 9-22)................................................. 1 1
3 ..... Poppet Valve (FFigure 9-23)............................................................ 1 1
4 1708317 Valve Section (Tilt) (FFigure 9-24)................................................... 1 1
5 1708298 Valve Section (Aux. 1) (FFigure 9-26).............................................. 1 1
6 1708299 Valve Section (Auxiliary Two) (FFigure 9-28).................................. 1 1
7 1708262 Valve Section (Outlet) (FFigure 9-30).............................................. 1 1
8 1581858 Kit-Capscrew ..................................................................................... 1 1
9 2102565 Steering Control Unit (FFigure 7-3)...................................................... 1 1
a 1678166 Plug ............................................................................................................ 1 1

FOOTNOTES:
a Not Illustrated

©2011 HYSTER COMPANY See Service Manual 9-45

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE (FIGURE 9-22)

LIFT AND LOWER — THREE, FOUR, AND FIVE FUNCTION

9-46 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE

LIFT AND LOWER – THREE, FOUR, AND FIVE FUNCTION

ITEM PART NO. DESCRIPTION QTY

1 1629196 Valve Section (Inlet) ............................................................................................ 1
2 1578712 Plug ................................................................................................................ 1
2 204128 Plug ............................................................................................................ 1
3 1581862 Kit-Valve (Manual Lowering) .......................................................................... 1
4 1629210 Plug ................................................................................................................ 1
5 1578904 Kit-Seal (Inlet) ................................................................................................. 1
6 1578911 Kit-Seal (Steering Control Unit Interface) ....................................................... 1
7 1578875 Shuttle Valve .................................................................................................. 1
8 1578888 Setscrew ......................................................................................................... 1
9 1569602 Plug ................................................................................................................ 1
10 1586280 Poppet ............................................................................................................ 1
11 1578876 Spring ............................................................................................................. 1
12 1578714 Plug ................................................................................................................ 1
13 1629209 Relief Valve (Main) ......................................................................................... 1
14 1580132 Kit-Relief Valve ........................................................................................... 1
15 1586279 Kit-Seal (Electro Hydraulic Poppet Valve) ...................................................... AR
16 1629211 Spring ............................................................................................................. 1
1578909 Kit-Seal (Master 3 Function) ........................................................................... 1
1578908 Kit-Seal (Master 4 Function) ........................................................................... 1
1578910 Kit-Seal (Master 5 Function) ........................................................................... 1

©2011 HYSTER COMPANY See Service Manual 9-47

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC HYDRAULIC POPPET VALVE (FIGURE 9-23)

THREE, FOUR AND FIVE FUNCTION

9-48 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC HYDRAULIC POPPET VALVE

THREE, FOUR AND FIVE FUNCTION

ITEM PART NO. DESCRIPTION QTY

1 1629201 Kit-Valve (Lower) ................................................................................................ 1
2 1629163 Nut .................................................................................................................. 1
3 1578710 Coil ................................................................................................................. 1
4 1629160 Tube (Solenoid) .............................................................................................. 1
5 1629165 Spring ............................................................................................................. 1
6 1629159 Poppet Valve .................................................................................................. 1
7 1586020 Sleeve ............................................................................................................ 1
8 1629200 Kit-Valve (Lift) ..................................................................................................... 1
9 1629163 Nut .................................................................................................................. 1
10 1629162 Coil ................................................................................................................. 1
11 1629161 Tube Assy (Solenoid) ..................................................................................... 1
12 1629164 Spring ............................................................................................................. 1
13 1629158 Poppet Valve .................................................................................................. 1
14 1586279 Kit-Seal (Electro Hydraulic Poppet Valve) .......................................................... 1

©2011 HYSTER COMPANY See Service Manual 9-49

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE (FIGURE 9-24)

TILT SECTION — THREE, FOUR, AND FIVE FUNCTION

9-50 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE

TILT SECTION – THREE, FOUR, AND FIVE FUNCTION

ITEM PART NO. DESCRIPTION QTY

1 b 1629197 Valve Section (Tilt) .............................................................................................. 1
1 c 1708317 Valve Section (Tilt) .............................................................................................. 1
2 1578713 Plug ................................................................................................................ 2
3 77442 Spring ............................................................................................................. 2
4 77443 Poppet ............................................................................................................ 2
5 1578905 Kit-Seal (Tilt) ................................................................................................... 1
6 1578889 Plug ................................................................................................................ 2
7 1578882 Spring ............................................................................................................. 2
8 1578883 Washer ........................................................................................................... 2
9 1580760 Spool End ....................................................................................................... 1
10 1580759 Spring ............................................................................................................. 1
11 1580099 Piston and Rod ............................................................................................... 1
12 1578878 Capscrew ....................................................................................................... 4
12 1664395 Capscrew ....................................................................................................... 4
13 1578711 Valve (Pressure Reducing) ............................................................................ 2
13 1578911 Kit-Seal (Steering Control Unit Interface) ................................................... 1
14 1578887 Setscrew ......................................................................................................... 1
a 1578912 Kit-Seal (Pressure Reducing Valve) ............................................................... 1

FOOTNOTES:
a Not Illustrated c S/N G004V04329G →
b → S/N G004V04328G

©2011 HYSTER COMPANY See Service Manual 9-51

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE (FIGURE 9-25)

AUXILIARY ONE SECTION — THREE, FOUR AND FIVE FUNCTION (→ S/N G004V04328G)

9-52 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE

AUXILIARY ONE SECTION – THREE, FOUR AND FIVE FUNCTION (→ S/N G004V04328G)

ITEM PART NO. DESCRIPTION QTY

1 1629198 Valve Section (Auxiliary One) ............................................................................. 1
2 1578713 Plug (Tilt/Auxiliary) ......................................................................................... 1
2 1578714 Plug (Lift) ........................................................................................................ 1
3 1578718 Cartridge Valve ............................................................................................... 1
3 1578886 Spring ......................................................................................................... 1
3 1629166 Sleeve ........................................................................................................ 1
3 266519 O-Ring ........................................................................................................ 2
4 77442 Spring ............................................................................................................. 1
5 77443 Poppet ............................................................................................................ 1
6 1578889 Plug ................................................................................................................ 2
7 1578906 Kit-Seal (Auxiliary Section) ............................................................................. 1
8 1578882 Spring ............................................................................................................. 2
9 1578883 Washer ........................................................................................................... 2
10 1578878 Capscrew ....................................................................................................... 4
11 1578711 Valve (Pressure Reducing) ............................................................................ 2
a 1578912 Kit-Seal (Pressure Reducing Valve) ........................................................... 1

FOOTNOTES:
a Not Illustrated

©2011 HYSTER COMPANY See Service Manual 9-53

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE (FIGURE 9-26)

AUXILIARY ONE SECTION — THREE, FOUR AND FIVE FUNCTION (S/N G004V04329G →)

9-54 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE

AUXILIARY ONE SECTION – THREE, FOUR AND FIVE FUNCTION (S/N G004V04329G →)

ITEM PART NO. DESCRIPTION QTY

1 1708263 Valve Section (Aux. 1) (3 Function) .................................................................... 1
1 1708298 Valve Section (Aux. 1) (4 and 5 Function) .......................................................... 1
2 1578714 Plug ................................................................................................................ 1
3 1578713 Plug ................................................................................................................ 1
3 77441 Plug ............................................................................................................ 1
4 77442 Spring ............................................................................................................. 2
5 77443 Poppet ............................................................................................................ 2
6 1578889 Plug ................................................................................................................ 1
7 1578906 Kit-Seal (Auxiliary Section) ............................................................................. 1
8 1578882 Spring ............................................................................................................. 2
9 1578883 Washer ........................................................................................................... 2
10 1664395 Capscrew ....................................................................................................... 4
11 1578711 Valve (Pressure Reducing) ............................................................................ 2
12 1578912 Kit-Seal (Pressure Reducing Valve) ............................................................... 2

©2011 HYSTER COMPANY See Service Manual 9-55

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE (FIGURE 9-27)

AUXILIARY TWO SECTION — FOUR AND FIVE FUNCTION (→ S/N G004V04328G)

9-56 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE

AUXILIARY TWO SECTION – FOUR AND FIVE FUNCTION (→ S/N G004V04328G)

ITEM PART NO. DESCRIPTION QTY

1 a 1633693 Valve Section ...................................................................................................... 1
2 1578713 Plug (Tilt/Auxiliary) ......................................................................................... 1
2 1578714 Plug (Lift) ........................................................................................................ 1
3 1578907 Kit-Seal (Auxiliary Section) ............................................................................. 1
4 77442 Spring ............................................................................................................. 1
5 77443 Poppet ............................................................................................................ 1
6 1578889 Plug ................................................................................................................ 2
7 1578882 Spring ............................................................................................................. 2
8 1578883 Washer ........................................................................................................... 2
9 1578878 Capscrew ....................................................................................................... 4
10 1578711 Valve (Pressure Reducing) ............................................................................ 2
11 1578912 Kit-Seal (Pressure Reducing Valve) ........................................................... 1

FOOTNOTES:
a Add Quantity One for Auxiliary Three on Five
Function

©2011 HYSTER COMPANY See Service Manual 9-57

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE (FIGURE 9-28)

AUXILIARY TWO SECTION — FOUR AND FIVE FUNCTION (S/N G004V04329G →)

9-58 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE

AUXILIARY TWO SECTION – FOUR AND FIVE FUNCTION (S/N G004V04329G →)

ITEM PART NO. DESCRIPTION QTY

1 1708299 Valve Section (Auxiliary Two) ............................................................................. 1
2 1578714 Plug ................................................................................................................ 1
3 1578713 Plug ................................................................................................................ 1
3 77441 Plug ............................................................................................................ 1
4 77442 Spring ............................................................................................................. 2
5 77443 Poppet ............................................................................................................ 2
6 1578889 Plug ................................................................................................................ 1
7 1578907 Kit-Seal (Auxiliary Section) ............................................................................. 1
8 1578882 Spring ............................................................................................................. 2
9 1578883 Washer ........................................................................................................... 2
10 1664395 Capscrew ....................................................................................................... 4
11 1578711 Valve (Pressure Reducing) ............................................................................ 2
12 1578912 Kit-Seal (Pressure Reducing Valve) ............................................................... 2

©2011 HYSTER COMPANY See Service Manual 9-59

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE (FIGURE 9-29)

OUTLET SECTION — THREE, FOUR AND FIVE FUNCTION (→ S/N G004V04328G)

9-60 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ELECTRONIC CONTROL VALVE

OUTLET SECTION – THREE, FOUR AND FIVE FUNCTION (→ S/N G004V04328G)

ITEM PART NO. DESCRIPTION QTY

1 1578704 Valve Section (Outlet) ......................................................................................... 1
2 1578707 Relief Valve (2250 PSI) (Secondary) ............................................................. 1
3 1580131 Kit-Seal ....................................................................................................... 1
4 1578715 Kit-Tie Rod (3 Function) ...................................................................................... 1
4 1580151 Kit-Tie Rod (4 Function) ...................................................................................... 1
4 1578750 Kit-Tie Rod (5 Function) ...................................................................................... 1
4 15055 Nut .................................................................................................................. 4

©2011 HYSTER COMPANY See Service Manual 9-61

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ELECTRONIC CONTROL VALVE (FIGURE 9-30)

OUTLET SECTION — THREE, FOUR AND FIVE FUNCTION (S/N G004V04329G →)

9-62 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ITEM PART NO. DESCRIPTION QTY

1 1708262 Valve Section (Outlet) ......................................................................................... 1
2 1708054 Relief Valve .................................................................................................... 1
3 1580131 Kit-Seal ....................................................................................................... 1
4 1578715 Kit-Tie Rod (Three Function) .............................................................................. 1
4 1580151 Kit-Tie Rod (Four Function) ................................................................................ 1
4 15055 Nut .................................................................................................................. 4
5 1695754 Disk ..................................................................................................................... 1
6 1678165 Solenoid Valve .................................................................................................... 1
6 1684487 Kit-Seal ........................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 9-63

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TILT CYLINDER INSTALLATION (FIGURE 9-31)

9-64 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TILT CYLINDER INSTALLATION

ITEM PART NO. DESCRIPTION QTY
1 1597381 Capscrew ........................................................................................................... 2
2 a 2066236 Cylinder Assy (FFigure 9-32).......................................................................... 2
2 b 2066237 Cylinder Assy (FFigure 9-32)............................................................................. 2
3 1581564 Lockwasher ....................................................................................................... 2
4 1581848 Nut ...................................................................................................................... 2
5 192429 Bushing ............................................................................................................. 2
6 1570303 Pin ...................................................................................................................... 2
7 16001 Grease Fitting .................................................................................................... 2
8 241079 Anchor ............................................................................................................... 2
9 1615240 Capscrew ........................................................................................................... 2
10 1566792 Rod End ............................................................................................................. 2
11 1581852 Washer ............................................................................................................... 2

FOOTNOTES:
a 5° Forward/6° Back b 8° Forward/5° Back

©2011 HYSTER COMPANY See Service Manual 9-65

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TILT CYLINDER (FIGURE 9-32)

9-66 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TILT CYLINDER
KEY:
A: 5 Degrees Forward/6 Degrees Back
B: 8 Degrees Forward/5 Degrees Back
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
2066236 Cylinder Assy ........................................................................................... 1 ..
2066237 Cylinder Assy ............................................................................................. .. 1
1 193554 Rod Wiper ............................................................................................. 1 1
2 1381049 Gland ..................................................................................................... 1 1
3 638248 Back-Up Ring ....................................................................................... 1 1
4 1381085 Rod Seal ............................................................................................... 1 1
5 334155 Wear Ring ............................................................................................. 1 1
6 1317007 Back-Up Ring ....................................................................................... 1 1
7 15884 O-Ring ................................................................................................... 1 1
8 1383056 Cylinder Rod ........................................................................................ 1 ..
8 1383057 Cylinder Rod .......................................................................................... .. 1
9 199917 O-Ring ................................................................................................... 1 1
10 2044378 Piston Seal ........................................................................................... 1 1
11 318067 Wear Ring ............................................................................................. 1 1
12 1380897 Piston .................................................................................................... 1 1
13 2036547 Locknut ................................................................................................. 1 1
14 1559451 Tube Wldmt-Cylinder ........................................................................... 1 ..
14 1559452 Tube Wldmt-Cylinder ............................................................................. .. 1
15 1378677 Kit-Seal (Includes Items 1, 3, 5-7, 9-11) ..................................................... 1 1

©2011 HYSTER COMPANY See Service Manual 9-67

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

TILT HOSES (FIGURE 9-33)

9-68 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TILT HOSES
ITEM PART NO. DESCRIPTION QTY
1 1516199 Fitting ................................................................................................................. 1
2 2076765 Hose Assy ......................................................................................................... 1
3 1488464 Fitting ................................................................................................................. 1
4 1487061 Fitting ................................................................................................................. 1
5 1487063 Fitting ................................................................................................................. 3
6 2084985 Hose Assy ......................................................................................................... 1
7 1480237 Nut ...................................................................................................................... 1
8 1605479 Hose Clamp (Dual Hose) .................................................................................. 1
9 1586627 Capscrew ........................................................................................................... 1
10 1486772 Fitting (Electronic Hydraulic) ............................................................................... 1
11 1473887 Fitting (Electronic Hydraulic) ........................................................................... 1
11 1516202 Fitting (Manual Hydraulic) ................................................................................ 1
12 1522426 Fitting ................................................................................................................. 1
13 2072224 Hose Assy ......................................................................................................... 2
14 2083765 Tube Assy (Electronic Hydraulic) ........................................................................ 1
14 2095707 Tube Assy (Manual Hydraulic) ........................................................................ 1

©2011 HYSTER COMPANY See Service Manual 9-69

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY HOSES (FIGURE 9-34)

9-70 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY HOSES
KEY:
A: Third Function
B: Fourth Function
C: Fifth Function
QTY
ITEM PART NO. DESCRIPTION A B C
1 1502809 Hose Clamp ...................................................................................... .. 1 ..
2 1360508 Clamp ............................................................................................... 1 .. ..
3 2091866 Hose Assy ........................................................................................ 1 .. ..
4 2104429 Hose Assy ........................................................................................ 1 .. ..
5 1502809 Hose Clamp ...................................................................................... .. .. 1
6 2087310 Hose Assy ......................................................................................... .. .. 1
7 1473897 Fitting ............................................................................................... .. .. 2
8 1473897 Fitting ............................................................................................... 1 .. ..
9 2092157 Hose and Tube Assy ......................................................................... .. .. 1
10 1502066 Clamp ............................................................................................... .. 1 ..
11 1502053 Clamp (Swivel) ................................................................................. .. 1 ..
12 1516202 Fitting ............................................................................................... 1 .. ..
13 2086134 Tube .................................................................................................. 1 .. ..
14 1473887 Fitting ............................................................................................... .. 2 ..
15 1480237 Nut .................................................................................................... .. 1 ..
16 1544157 Clip .................................................................................................... .. 1 ..
17 1527879 Capscrew ......................................................................................... .. 1 ..
18 2086157 Hose Assy ........................................................................................ .. 1 ..
19 2084867 Hose Assy ........................................................................................ .. 1 ..
20 1502809 Hose Clamp ...................................................................................... 1 .. ..
21 1465489 Hose Clamp ...................................................................................... .. 1 ..
22 1360507 Clamp ............................................................................................... .. 2 ..

©2011 HYSTER COMPANY See Service Manual 9-71

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

VENT LINE GROUP (FIGURE 9-35)

ITEM PART NO. DESCRIPTION QTY

1 ..... Hydraulic Control Valve (FFigure 9-18, FFigure 9-20, FFigure 9-10)........ 1
2 1502007 Hose Clamp ....................................................................................................... 2
3 980929 Hose Assy ......................................................................................................... 1
4 1502066 Clamp ................................................................................................................. 1
5 1502059 Clamp ................................................................................................................. 1
6 110178 Fitting (Two Stage Limited Free-Lift and Three Stage Full ........................... 1
6 222443 Fitting (Two Stage Full Free-Lift and No Mast) .............................................. 1

9-72 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HOIST HOSE AND ATTACHING PARTS (FIGURE 9-36)

ITEM PART NO. DESCRIPTION QTY

1 1473898 Fitting ................................................................................................................. 1
2 2076763 Hose Assy (Hoist) ............................................................................................. 1
3 2061646 Fitting (Diagnostic) ........................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 9-73

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NOTES

9-74 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

10 MAST-TWO STAGE LIMITED FREE-LIFT

 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 10
MAST-TWO STAGE LIMITED FREE-LIFT

DESCRIPTION PAGE

AUXILIARY TUBE EXTENSIONS

TWO STAGE LIMITED FREE LIFT - WITHOUT QUICK DISCONNECT
FITTINGS (S/N B586V01930G →) (S/N B587V02097G →) ..................................................................... 10-26
TWO STAGE LIMITED FREE LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B586V01930G →) (S/N B587V02097G →) ..................................................................... 10-28
TWO STAGE LIMITED FREE LIFT - E-HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B586V01930G →) (S/N B587V02097G →) ..................................................................... 10-30
TWO STAGE LIMITED FREE-LIFT (→ S/N B586V01929G) (→ S/N B587V02096G) ............................. 10-22
TWO STAGE LIMITED FREE-LIFT - INTEGRAL SIDE-SHIFT CARRIAGE (→ S/N B586V01929G)
(→ S/N B587V02096G) .............................................................................................................................. 10-24
CARRIAGE
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-20
HEADER HOSE
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
TWO STAGE LIMITED FREE-LIFT - S80FT .............................................................................................. 10-10
TWO STAGE LIMITED FREE-LIFT - S100-120FT ..................................................................................... 10-12
OUTER MAST
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-2

©2011 HYSTER COMPANY See Service Manual 10-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

OUTER MAST (FIGURE 10-1)

TWO STAGE LIMITED FREE-LIFT

10-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

OUTER MAST
TWO STAGE LIMITED FREE-LIFT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3000 mm 3600 mm
ITEM 1 2 3 4 (118.1 in.) (141.7 in.)
Mast B586 B586
Group Number 3000 3600
Mast Assy 2078116 2078122
1 Outer Mast 1541420 1541426

S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2740 mm 3340 mm 3940 mm
ITEM 1 2 3 4 (107.9 in.) (131.5 in.) (155.1 in.)
Mast B587 B587 B587
Group Number 2740 3340 3940
Mast Assy 2078158 2078164 2078170
1 Outer Mast 1541420 1541426 1541432

KEY:
A: S80FT
B: S100-120FT
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Mast Assy ................................................................................................... 1 1
1 a. . . . . Outer Mast ............................................................................................. 1 1
2 1500744 Stubshaft ........................................................................................... 2 2
3 b 1399203 Load Roller ("A") (126.75/126.49) .......................................................... 2 2
3 1399204 Load Roller ("B") (127.51/127.25) .......................................................... 2 2
3 1399205 Load Roller ("C") (128.27/128.01) ......................................................... 2 2
4 1465072 Snap Ring .............................................................................................. 2 2
5 16002 Grease Fitting ........................................................................................ 2 2
6 1507004 Bushing .................................................................................................. 4 4
7 1646821 Plug ........................................................................................................ 2 2
8 1646820 Plug ........................................................................................................ 2 2
9 292591 Capscrew ............................................................................................... 4 4
10 296430 Washer .................................................................................................. 4 4
11 1474354 Cap ........................................................................................................ 2 2
12 192429 Bushing .................................................................................................. 2 2
13 104506 O-Ring ................................................................................................... 4 4
14 161273 Shim (0.020 in.) ..................................................................................... AR AR
15 161272 Shim (0.007 in.) ..................................................................................... AR AR
16 104264 Wear Strip .............................................................................................. 2 2

FOOTNOTES:
a Refer to Table b Replace with larger depending on wear

©2011 HYSTER COMPANY See Service Manual 10-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INNER MAST (FIGURE 10-2)

TWO STAGE LIMITED FREE-LIFT

10-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INNER MAST
TWO STAGE LIMITED FREE-LIFT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3000 mm 3600 mm
ITEM 1 2 3 4 (118.1 in.) (141.7 in.)
Mast B586 B586
Group Number 3000 3600
Mast Assy 2078116 2078122
1 Inner Mast 1401800 1401806

S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2740 mm 3340 mm 3940 mm
ITEM 1 2 3 4 (107.9 in.) (131.5 in.) (155.1 in.)
Mast B587 B587 B587
Group Number 2740 3340 3940
Mast Assy 2078158 2078164 2078170
1 Inner Mast 1401800 1401806 1401812

KEY:
A: S80FT
B: S100-120FT
QTY
ITEM PART NO. DESCRIPTION A B
b. . . . . Mast Assy ................................................................................................... 1 1
1 b. . . . . Inner Mast .............................................................................................. 1 1
2 c 1399203 Load Roller ("A") (126.75/126.49) .......................................................... 2 2
2 1399204 Load Roller ("B") (127.51/127.25) .......................................................... 2 2
2 1399205 Load Roller ("C") (128.27/128.01) ......................................................... 2 2
3 1465072 Snap Ring .............................................................................................. 2 2
4 126765 Shim ....................................................................................................... 12 12
5 1387745 Chain Sheave ........................................................................................ 2 ..
5 1387744 Chain Sheave ........................................................................................ .. 2
6 126764 Load Roller ........................................................................................ 1 1
7 40667 Snap Ring .......................................................................................... 2 2
8 a 1389959 Bracket ................................................................................................... 2 2
9 a 1581852 Washer .................................................................................................. 2 2
10 a 1581590 Capscrew ............................................................................................... 2 2

FOOTNOTES:
a Not used on all applications c Replace with larger depenfing on wear
b Refer to Table

©2011 HYSTER COMPANY See Service Manual 10-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MAIN LIFT (FIGURE 10-3)

TWO STAGE LIMITED FREE-LIFT

10-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MAIN LIFT
TWO STAGE LIMITED FREE-LIFT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3000 mm 3600 mm
ITEM 1 2 3 4 (118.1 in.) (141.7 in.)
Mast B586 B586
Group Number 3000 3600
2 Chain 243975 365599
3 Hose Assy (RH) 1399084 1399096
4 Hose Assy (LH) 1399098 1399110

S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2740 mm 3340 mm 3940 mm
ITEM 1 2 3 4 (107.9 in.) (131.5 in.) (155.1 in.)
Mast B587 B587 B587
Group Number 2740 3340 3940
2 Chain 338647 356916 1395480
3 Hose Assy (RH) 1399079 1399091 1399103
4 Hose Assy (LH) 1399093 1399105 1399117

ITEM PART NO. DESCRIPTION QTY

1 ..... Main Cylinder (FFigure 10-5).......................................................................... 2
2 a. . . . . Chain .............................................................................................................. 1
3 a. . . . . Hose Assy (RH) ............................................................................................ 1
4 a. . . . . Hose Assy (LH) ............................................................................................. 1
5 304523 Snap Ring ...................................................................................................... 2
6 332061 Washer .......................................................................................................... 2
7 142247 Shim ............................................................................................................... AR
8 1325120 Shim ............................................................................................................... AR
9 1487096 Fitting ............................................................................................................ 1
10 1626478 Washer ........................................................................................................... 4
11 1581585 Capscrew ...................................................................................................... 2
12 1474399 Bracket Wldmt .............................................................................................. 2
13 1581566 Nut ................................................................................................................. 2
14 1581588 Capscrew ...................................................................................................... 4
15 1626478 Washer ........................................................................................................... 4
16 1477559 Bracket ........................................................................................................... 1
17 1389846 Spacer ........................................................................................................... 2
18 12891 Snap Ring ...................................................................................................... 2
19 1388019 Housing ......................................................................................................... 1
20 14595 Plug Assembly .............................................................................................. 1
20 16484 O-Ring ....................................................................................................... 1
21 1581583 Capscrew ...................................................................................................... 2
22 c 1550197 Lowering Control Valve .................................................................................. 1
22 b 1550198 Lowering Control Valve ............................................................................... ..
22 16982 O-Ring ....................................................................................................... 1
©2011 HYSTER COMPANY See Service Manual 10-7
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MAIN LIFT
TWO STAGE LIMITED FREE-LIFT

ITEM PART NO. DESCRIPTION QTY

22 280154 O-Ring ....................................................................................................... 1
23 14603 Plug ................................................................................................................ 1
23 16486 O-Ring ....................................................................................................... 1
24 1487068 Fitting ............................................................................................................ 1
24 16484 O-Ring ....................................................................................................... 1
24 252729 O-Ring ....................................................................................................... 1
25 2046871 Fitting ............................................................................................................ 1
26 379405 Clamp ............................................................................................................ 4
27 1550239 Hose Assy ...................................................................................................... 1
28 2075534
4604939 Hose Assy ...................................................................................................... 1
29 1550436 Bracket (LH) ................................................................................................... 1
29 1550438 Bracket (RH) ................................................................................................... 1
30 1550157 Hyd Velocity Fuse .......................................................................................... 2
31 1465585 Hose Clamp ................................................................................................... 4
32 1360529 Clamp ............................................................................................................ 4
33 110178 Fitting ............................................................................................................ 2
33 16483 O-Ring ....................................................................................................... 2
34 15222 Cotter Pin ...................................................................................................... 2
35 1581896 Nut ................................................................................................................. 4
36 c 1331990 Chain Anchor .................................................................................................. 2
36 b 1331991 Chain Anchor ................................................................................................ 2
37 c 327591 Pin .................................................................................................................. 2
37 b 339932 Pin .................................................................................................................. 2
38 1581586 Capscrew ...................................................................................................... 2
39 1626490 Washer .......................................................................................................... 2

FOOTNOTES:
a Refer to Table c S80FT
b S100-120FT

10-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 10-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MAIN LIFT CYLINDER (FIGURE 10-4)

TWO STAGE LIMITED FREE-LIFT — S80FT

10-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MAIN LIFT CYLINDER

TWO STAGE LIMITED FREE-LIFT – S80FT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3000 mm 3600 mm
1 2 3 4 (118.1 in.) (141.7 in.)
ITEM Mast B586 B586
Group Number 3000 3600
Cylinder
8527601 8527607
Group Number
Cylinder Assy 2074622 2074629
1 Tube Wldmt- 2075005 2075011
Cylinder
2 Cylinder Rod 2075442 2075127

ITEM PART NO. DESCRIPTION QTY

a. . . . . Cylinder Assy ...................................................................................................... 2
1 a. . . . . Tube Wldmt-Cylinder ...................................................................................... 1
2 a. . . . . Cylinder Rod ................................................................................................... 1
3 57664 O-Ring ............................................................................................................ 1
4 2033243 Gland .............................................................................................................. 1
5 215425 Wear Ring ...................................................................................................... 1
6 270077 Rod Seal ......................................................................................................... 1
7 638249 Back-Up Ring ................................................................................................. 2
8 1383066 Rod Wiper ...................................................................................................... 1
9 1381061 Rod Seal ......................................................................................................... 1
10 297532 Wear Ring ...................................................................................................... 1
11 2035784 Kit-Seal (Includes Items 3, 5-10) ........................................................................ 1

FOOTNOTES:
a Refer to Table

©2011 HYSTER COMPANY See Service Manual 10-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MAIN LIFT CYLINDER (FIGURE 10-5)

TWO STAGE LIMITED FREE-LIFT — S100-120FT

10-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MAIN LIFT CYLINDER

TWO STAGE LIMITED FREE-LIFT – S100-120FT
S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2740 mm 3340 mm 3940 mm
1 2 3 4 (107.9 in.) (131.5 in.) (155.1 in.)
ITEM Mast B587 B587 B587
Group Number 2740 3340 3940
Cylinder
8527701 8527707 8527713
Group Number
Cylinder Assy 2074895 2074901 2074954
1 Tube Wldmt- 2075089 2075095 2075101
Cylinder
2 Cylinder Rod 2075151 2075157 2075163

ITEM PART NO. DESCRIPTION QTY

a. . . . . Cylinder Assy ...................................................................................................... 2
1 a. . . . . Tube Wldmt-Cylinder ...................................................................................... 1
2 a. . . . . Cylinder Rod ................................................................................................... 1
3 15879 O-Ring ............................................................................................................ 1
4 2033281 Gland .............................................................................................................. 1
5 297532 Wear Ring ...................................................................................................... 1
6 327807 Rod Seal ......................................................................................................... 1
7 327808 Back-Up Ring ................................................................................................. 1
8 1383067 Rod Wiper ...................................................................................................... 1
9 351532 Back-Up Ring ................................................................................................. 1
10 1381062 Rod Seal ......................................................................................................... 1
11 351531 Wear Ring ...................................................................................................... 1
2035785 Kit-Seal (Includes Items 3, 5-11) ........................................................................ 1

FOOTNOTES:
a Refer to Table

©2011 HYSTER COMPANY See Service Manual 10-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HEADER HOSE (FIGURE 10-6)

TWO STAGE LIMITED FREE-LIFT

10-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HEADER HOSE
TWO STAGE LIMITED FREE-LIFT
FIVE FUNCTION S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3000 mm 3600 mm
ITEM 1 2 3 4 (118.1 in.) (141.7 in.)
Mast B586 B586
Group Number 3000 3600
Mast Assy 2078116 2078122
1 Hose Assy 2077921 2077927
2 Hose Assy 2077921 2077927
3 Hose Assy 2077914 2077914
4 Hose Assy 2078050 2078056

FOUR FUNCTION S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3000 mm 3600 mm
ITEM 1 2 3 4 (118.1 in.) (141.7 in.)
Mast B586 B586
Group Number 3000 3600
Mast Assy 2078116 2078122
1 Hose Assy 2077921 2077927
2 Hose Assy 2077921 2077927

THREE FUNCTION S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3000 mm 3600 mm
ITEM 1 2 3 4 (118.1 in.) (141.7 in.)
Mast B586 B586
Group Number 3000 3600
Mast Assy 2078116 2078122
1 Hose Assy 2077921 2077927
2 Hose Assy 2077921 2077927

©2011 HYSTER COMPANY See Service Manual 10-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HEADER HOSE
TWO STAGE LIMITED FREE-LIFT
FIVE FUNCTION S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2740 mm 3340 mm 3940 mm
ITEM 1 2 3 4 (107.9 in.) (131.5 in.) (155.1 in.)
Mast B587 B587 B587
Group Number 2740 3340 3940
Mast Assy 2078158 2078164 2078170
1 Hose Assy 2077987 2077993 2077999
2 Hose Assy 2077987 2077993 2077999
3 Hose Assy 2077914 2077914 2077914
4 Hose Assy 2078050 2078056 2078062

FOUR FUNCTION S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2740 mm 3340 mm 3940 mm
ITEM 1 2 3 4 (107.9 in.) (131.5 in.) (155.1 in.)
Mast B587 B587 B587
Group Number 2740 3340 3940
Mast Assy 2078158 2078164 2078170
1 Hose Assy 2077987 2077993 2077999
2 Hose Assy 2077987 2077993 2077999

THREE FUNCTION S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2740 mm 3340 mm 3940 mm
ITEM 1 2 3 4 (107.9 in.) (131.5 in.) (155.1 in.)
Mast B587 B587 B587
Group Number 2740 3340 3940
Mast Assy 2078158 2078164 2078170
1 Hose Assy 2077987 2077993 2077999
2 Hose Assy 2077987 2077993 2077999

KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
a. . . . . Mast Assy .......................................................................................... 1 1 1
1 a. . . . . Hose Assy ..................................................................................... 2 .. 2
2 a. . . . . Hose Assy ..................................................................................... 2 .. 2
3 a. . . . . Hose Assy ..................................................................................... .. .. 1

10-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HEADER HOSE
TWO STAGE LIMITED FREE-LIFT
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
4 a. . . . . Hose Assy ..................................................................................... .. .. 2
5 1599434 Fitting ............................................................................................ 2 4 4
5 265731 O-Ring ...................................................................................... 4 8 8
6 1581743 Capscrew ...................................................................................... 4 4 4
7 1581557 Washer .......................................................................................... 4 4 4
8 1581567 Nut ................................................................................................. 4 4 4
9 1500175 Grommet ....................................................................................... 2 4 4
10 816591 Fitting (Includes Nut) ..................................................................... 2 4 4
10 816593 Locknut .......................................................................................... 2 4 4
11 1550433 Tube Assy ..................................................................................... 1 2 2
12 1550434 Tube Assy ..................................................................................... 1 2 2
13 1550435 Plate .............................................................................................. 1 1 1
14 bc 1597853 Plate (Without Side Shift) .............................................................. .. .. 1
14 de 1705595 Bracket (Without Side-Shift) .......................................................... .. .. 1
14 de 136692 Nut (Without Side-Shift) ................................................................ .. .. 1
14 1599321 Plate (With Side-Shift) ................................................................... .. .. 1
15 358287 Bracket .......................................................................................... .. .. 1
16 bc 1581563 Lockwasher ................................................................................... .. .. 2
16 de 1581563 Lockwasher (Without Side-Shift) ................................................... .. .. 4
17 bc 1597852 Capscrew ...................................................................................... .. .. 2
17 de 1597442 Capscrew (Alternate Part) ............................................................. 2 2 2
17 de 1597442 Capscrew (Without Side-Shif) ....................................................... .. .. 3
18 358286 Strain Relief ................................................................................... .. .. 1
19 1473887 Fitting ............................................................................................ .. .. 4
19 16484 O-Ring ...................................................................................... .. .. 4
20 358289 Hose Reel ..................................................................................... .. .. 1
20 672563 Kit-Seal ..................................................................................... .. .. 1
21 1581594 Capscrew ...................................................................................... .. .. 2
22 1581559 Washer .......................................................................................... .. .. 2
23 1618437 Plate .............................................................................................. .. .. 1
24 1502809 Hose Clamp .................................................................................. .. .. 2
25 1360507 Clamp ............................................................................................ .. .. 2
26 1465489 Hose Clamp .................................................................................. 2 4 4
27 1360507 Clamp ............................................................................................ 2 4 4
28 1581565 Nut ................................................................................................. 2 4 4
29 1477578 Spacer ........................................................................................... 1 2 2
30 2035791 Hose Clamp .................................................................................. 1 2 2
31 1581577 Capscrew ...................................................................................... 2 4 4
32 1495279 Hose Sheave ................................................................................. 1 2 2
32 332057 Bushing ..................................................................................... 1 2 2
33 1477570 Stubshaft ....................................................................................... 1 2 2
34 1581564 Lockwasher ................................................................................... 1 2 2
35 1581594 Capscrew ...................................................................................... 1 2 2
36 1345190 Washer .......................................................................................... 1 2 2

©2011 HYSTER COMPANY See Service Manual 10-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a Refer to Table d S/N B586V01928G →
b → S/N B586V01927G e S/N B587V02075G →
c → S/N B587V02074G

10-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 10-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

CARRIAGE (FIGURE 10-7)

TWO STAGE LIMITED FREE-LIFT

10-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

CARRIAGE
TWO STAGE LIMITED FREE-LIFT
KEY:
A: Class III
B: Class IV
C: Class III (Attachment)
QTY
ITEM PART NO. DESCRIPTION A B C
1401660 Carriage (42 in.) ................................................................................ 1 .. ..
1401662 Carriage (42 in.) ................................................................................ .. 1 ..
1401664 Carriage (42 in.) ................................................................................ .. .. 1
1 1401630 Carriage Wldmt (42 in.) ................................................................. 1 .. ..
1 1401632 Carriage Wldmt (42 in.) ................................................................. .. 1 ..
1 1401634 Carriage Wldmt (42 in.) ................................................................. .. .. 1
2 1511883 Load Roller ("B") (104.44/104.18) ................................................. 6 6 6
3 126765 Shim .............................................................................................. 24 24 24
4 1465072 Snap Ring ..................................................................................... 6 6 6
5 1399224 Spacer ........................................................................................... 2 2 2
6 1387285 Chain Anchor ................................................................................ 2 .. ..
6 1387286 Chain Anchor ................................................................................ .. 2 2
7 327591 Pin ................................................................................................. 2 .. ..
7 339932 Pin ................................................................................................. .. 2 2
8 15222 Cotter Pin ...................................................................................... 2 2 2
9 1581896 Nut ................................................................................................. 4 4 4
10 15224 Cotter Pin ...................................................................................... 2 2 2
11 1387993 Side Roller ..................................................................................... .. .. 2
12 66333 Roll Pin .......................................................................................... .. .. 2
13 1465177 Bracket (Roller) ............................................................................. .. .. 2
14 192425 Shim (0.062 in.) ............................................................................. .. .. AR
15 192424 Shim (0.030 in.) ............................................................................. .. .. AR
16 1465028 Pin ................................................................................................. .. .. 2
17 292528 Capscrew ...................................................................................... .. .. 4
18 292683 Lockwasher ................................................................................... .. .. 4
19 16001 Grease Fitting ................................................................................ .. .. 2

©2011 HYSTER COMPANY See Service Manual 10-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 10-8)

TWO STAGE LIMITED FREE-LIFT (→ S/N B586V01929G) (→ S/N B587V02096G)

10-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

TWO STAGE LIMITED FREE-LIFT (→ S/N B586V01929G) (→ S/N B587V02096G)
KEY:
A: B586, Three Function
B: B586, Four Function
C: B587, Three Function
D: B587, Four Function
QTY
ITEM PART NO. DESCRIPTION A B C D
1 1529016 Fitting ........................................................................................ 2 2 2 2
1 265731 O-Ring .................................................................................. 1 1 1 1
2 c 816591 Fitting (Includes Nut) ................................................................. 2 2 2 2
2 265731 O-Ring .................................................................................. 2 2 2 2
3 de 1643681 Bracket (LH) .............................................................................. 1 1 1 1
3 1705597 Bracket (LH) .............................................................................. 1 1 1 1
3 ade 1528778 Capscrew .................................................................................. 2 2 2 2
3 afg 1597442 Capscrew .................................................................................. 2 2 2 2
3 afg 1581563 Lockwasher ............................................................................... 2 2 2 2
4 2085596 Tube Assy ................................................................................. 1 .. .. ..
4 2089855 Tube Assy ................................................................................. .. .. 1 ..
4 b 2085831 Tube Assy ................................................................................. 1 .. .. ..
5 2085597 Tube Assy ................................................................................. 1 .. .. ..
5 2089856 Tube Assy ................................................................................. .. .. 1 ..
5 b 2085830 Tube Assy ................................................................................. 1 .. .. ..
6 2085659 Tube Assy ................................................................................. .. 1 .. ..
6 2089857 Tube Assy ................................................................................. .. .. 1 1
6 b 2085832 Tube Assy ................................................................................. .. .. .. 1
7 2085660 Tube Assy ................................................................................. .. 1 .. ..
7 2089858 Tube Assy ................................................................................. .. .. 1 1
7 b 2085833 Tube Assy ................................................................................. .. .. .. 1
8 1622610 Fitting ........................................................................................ 2 2 2 2
8 16484 O-Ring .................................................................................. 1 1 1 1
9 1377953 Quick Disconnect Fitting ........................................................... 2 2 2 2
10 1377954 Fitting ........................................................................................ 2 2 2 2
11 181298 Dust Cap ................................................................................... 2 2 2 2
12 1473887 Fitting ........................................................................................ 2 2 2 2
12 16484 O-Ring .................................................................................. 1 1 1 1
13 2087565 Drain Valve ............................................................................... 1 1 1 1
14 16541 Fitting ........................................................................................ 1 1 1 1
14 16484 O-Ring .................................................................................. 1 1 1 1
15 d 1643341 Bracket (RH) ............................................................................. 1 1 1 1
15 fg 1705595 Bracket ...................................................................................... 1 1 1 1
15 ade 1528778 Capscrew .................................................................................. 2 2 2 2
15 afg 1597442 Capscrew .................................................................................. 2 2 2 2
15 afg 1581563 Lockwasher ............................................................................... 2 2 2 2

FOOTNOTES:
a Not Illustrated e → S/N B587V02074G
b Used With Attachment Carriage f S/N B586V01928G →
c Used Without Quick Disconnect Fittings g S/N B857V02075G →
d → S/N B586V01927G

©2011 HYSTER COMPANY See Service Manual 10-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 10-9)

TWO STAGE LIMITED FREE-LIFT — INTEGRAL SIDE-SHIFT CARRIAGE (→ S/N B586V01929G)
(→ S/N B587V02096G)

10-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

TWO STAGE LIMITED FREE-LIFT – INTEGRAL SIDE-SHIFT CARRIAGE (→ S/N B586V01929G)
(→ S/N B587V02096G)
KEY:
A: B856, Four Function
B: B587, Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1529016 Fitting ......................................................................................................... 2 2
1 265731 O-Ring ................................................................................................... 1 1
2 a 816591 Fitting (Includes Nut) .................................................................................. 2 2
2 265731 O-Ring ................................................................................................... 1 1
3 1643681 Bracket ....................................................................................................... 1 1
3 1703560 Capscrew ................................................................................................... 2 2
3 1597442 Capscrew ................................................................................................... 2 2
4 2087565 Drain Valve ................................................................................................. 1 1
5 16541 Fitting ......................................................................................................... 1 1
5 16484 O-Ring ................................................................................................... 1 1
6 2085677 Tube Assy .................................................................................................. 1 ..
6 2089861 Tube Assy .................................................................................................. .. 1
7 2085678 Tube Assy .................................................................................................. 1 ..
7 2089862 Tube Assy .................................................................................................. .. 1
8 1622610 Fitting ......................................................................................................... 2 2
8 16484 O-Ring ................................................................................................... 1 1
9 1377953 Quick Disconnect Fitting ............................................................................ 2 2
10 1377954 Fitting ......................................................................................................... 2 2
11 181298 Dust Cap .................................................................................................... 2 2
12 1473887 Fitting ......................................................................................................... 2 2
12 16484 O-Ring ................................................................................................... 1 1

FOOTNOTES:
a Used Without Quick Disconnect Fittings

©2011 HYSTER COMPANY See Service Manual 10-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 10-10)

TWO STAGE LIMITED FREE LIFT — WITHOUT QUICK DISCONNECT FITTINGS (S/N B586V01930G →)
(S/N B587V02097G →)

10-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

TWO STAGE LIMITED FREE LIFT – WITHOUT QUICK DISCONNECT FITTINGS (S/N B586V01930G →)
(S/N B587V02097G →)
KEY:
A: B586, Three Function
B: B586, Four Function
C: B587, Three Function
D: B587, Four Function
QTY
ITEM PART NO. DESCRIPTION A B C D
1 2085660 Tube Assy ................................................................................. .. 1 .. ..
1 b 2085678 Tube Assy ................................................................................. .. 1 .. ..
1 2089858 Tube Assy ................................................................................. .. .. .. 1
1 a 2085833 Tube Assy ................................................................................. .. .. .. 1
1 b 2089862 Tube Assy ................................................................................. .. .. .. 1
2 816591 Fitting (Includes Nut) ................................................................. 2 4 2 4
3 1705597 Bracket (LH) .............................................................................. .. 1 .. 1
3 b 1643681 Bracket (LH) .............................................................................. .. 1 .. 1
4 1581563 Lockwasher ............................................................................... 2 4 2 4
5 1597443 Bolt ............................................................................................ 2 4 2 4
6 2085659 Tube Assy ................................................................................. .. 1 .. ..
6 a 2085677 Tube Assy ................................................................................. .. 1 .. ..
6 2089857 Tube Assy ................................................................................. .. .. .. 1
6 a 2085832 Tube Assy ................................................................................. .. .. .. 1
6 b 2089861 Tube Assy ................................................................................. .. .. .. 1
7 1705595 Bracket (RH) ............................................................................. 1 1 1 1
8 2085597 Tube Assy ................................................................................. 1 1 .. ..
8 2089856 Tube Assy ................................................................................. .. .. 1 1
8 a 2085831 Tube Assy ................................................................................. .. .. 1 1
9 2085596 Tube Assy ................................................................................. 1 1 .. ..
9 2089855 Tube Assy ................................................................................. .. .. 1 1
9 a 2085830 Tube Assy ................................................................................. .. .. 1 1

FOOTNOTES:
a Used with Attachment Carriage b Used with ISS Carriage

©2011 HYSTER COMPANY See Service Manual 10-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 10-11)

TWO STAGE LIMITED FREE LIFT — MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B586V01930G →) (S/N B587V02097G →)

10-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

KEY:
A: B586, Three Function
B: B586, Four Function
C: B587, Three Function
D: B587, Four Function
QTY
ITEM PART NO. DESCRIPTION A B C D
1 1705595 Bracket (RH) ............................................................................. 1 1 1 1
2 1473887 Fitting ........................................................................................ 2 4 2 4
3 1377954 Fitting (Quick Disconnect) ......................................................... 2 4 2 4
4 1377953 Quick Disconnect Fitting ........................................................... 2 4 2 4
5 1708368 Dust Cover ................................................................................ 2 4 2 4
6 1708365 Bulkhead (Fitting) ...................................................................... 2 4 2 4
7 1581563 Lockwasher ............................................................................... 2 4 2 4
8 1597443 Bolt ............................................................................................ 2 4 2 4
9 1705597 Bracket (LH) .............................................................................. .. .. 1 1
9 b 1643681 Bracket (LH) .............................................................................. .. 1 .. 1
10 2085597 Tube Assy ................................................................................. 1 1 .. ..
10 2089856 Tube Assy ................................................................................. .. .. 1 1
10 a 2085831 Tube Assy ................................................................................. .. .. 1 1
11 2085660 Tube Assy ................................................................................. .. 1 .. ..
11 b 2085678 Tube Assy ................................................................................. .. 1 .. ..
11 2089858 Tube Assy ................................................................................. .. .. .. 1
11 b 2089862 Tube Assy ................................................................................. .. .. .. 1
11 a 2085833 Tube Assy ................................................................................. .. .. .. 1
12 2085659 Tube Assy ................................................................................. .. 1 .. ..
12 b 2085677 Tube Assy ................................................................................. .. 1 .. ..
12 2089857 Tube Assy ................................................................................. .. .. .. 1
12 b 2089861 Tube Assy ................................................................................. .. .. .. 1
12 a 2085832 Tube Assy ................................................................................. .. .. .. 1
13 2085596 Tube Assy ................................................................................. 1 1 .. ..
13 2089855 Tube Assy ................................................................................. .. .. 1 1
13 a 2085830 Tube Assy ................................................................................. .. .. 1 1

FOOTNOTES:
a Use with Attachment Carriage b Use With ISS Carriage

©2011 HYSTER COMPANY See Service Manual 10-29

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 10-12)

TWO STAGE LIMITED FREE LIFT — E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B586V01930G →) (S/N B587V02097G →)

10-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

TWO STAGE LIMITED FREE LIFT – E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B586V01930G →) (S/N B587V02097G →)
KEY:
A: B586, Three Function
B: B586, Four Function
C: B587, Three Function
D: B587, Four Function
QTY
ITEM PART NO. DESCRIPTION A B C D
1 1487095 Fitting ........................................................................................ 2 4 2 4
2 4604565 Hose Assy ................................................................................. 1 2 1 2
3 4604566 Hose Assy ................................................................................. 1 2 1 2
4 2111754 Valve (Single Aux) .................................................................... 1 .. 1 ..
4 a 2111754 Valve (Single Aux) .................................................................... .. 1 .. 1
4 2111755 Valve (Dual Aux) ....................................................................... .. 1 .. 1
5 110178 Fitting ........................................................................................ 1 1 1 1
5 16483 O-Ring .................................................................................. 1 1 1 1
6 1527979 Hose Clamp .............................................................................. 4 4 4 4
7 2046871 Fitting ........................................................................................ 1 1 1 1
8 1529016 Fitting ........................................................................................ 2 4 2 4
9 1473887 Fitting ........................................................................................ 2 4 2 4
10 1377954 Fitting (Quick Disconnect) ......................................................... 2 4 2 4
11 1377953 Quick Disconnect Fitting ........................................................... 2 4 2 4
12 1708368 Dust Cover ................................................................................ 2 4 2 4
13 1708365 Bulkhead (Fitting) ...................................................................... 2 4 2 4
14 1705595 Bracket (RH) ............................................................................. 1 1 1 1
15 1581563 Lockwasher ............................................................................... 2 4 2 4
16 1597443 Bolt ............................................................................................ 2 4 2 4
17 816593 Locknut ..................................................................................... 2 4 2 4
18 2085597 Tube Assy ................................................................................. 1 1 .. ..
18 b 2089856 Tube Assy ................................................................................. .. 1 .. 1
18 b 2085831 Tube Assy ................................................................................. .. .. 1 1
19 2085596 Tube Assy ................................................................................. 1 1 .. ..
19 2089855 Tube Assy ................................................................................. .. .. 1 1
19 b 2085830 Tube Assy ................................................................................. .. .. 1 1
20 1708373 Bracket ...................................................................................... 1 1 1 1
21 1527885 Capscrew .................................................................................. 2 2 2 2
22 2085660 Tube Assy ................................................................................. .. 1 .. ..
22 a 2085678 Tube Assy ................................................................................. .. 1 .. ..
22 2089858 Tube Assy ................................................................................. .. .. .. 1
22 a 2089862 Tube Assy ................................................................................. .. .. .. 1
22 b 2085833 Tube Assy ................................................................................. .. .. .. 1
23 2085659 Tube Assy ................................................................................. .. 1 .. ..
23 a 2085677 Tube Assy ................................................................................. .. 1 .. ..
23 2089857 Tube Assy ................................................................................. .. .. .. 1
23 a 2089861 Tube Assy ................................................................................. .. .. .. 1
23 b 2085832 Tube Assy ................................................................................. .. .. .. 1
24 1705597 Bracket (LH) .............................................................................. 1 1 1 1
24 a 1643681 Bracket (LH) .............................................................................. .. 1 .. 1
25 292505 Capscrew .................................................................................. 2 2 2 2
26 1614069 Hose ......................................................................................... 1 1 1 1

©2011 HYSTER COMPANY See Service Manual 10-31

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS

TWO STAGE LIMITED FREE LIFT – E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B586V01930G →) (S/N B587V02097G →)
KEY:
A: B586, Three Function
B: B586, Four Function
C: B587, Three Function
D: B587, Four Function
QTY
ITEM PART NO. DESCRIPTION A B C D
27 1486737 Fitting ........................................................................................ 2 2 2 2

FOOTNOTES:
a Use With ISS Carriage b Used with Attachment Carriage

10-32 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

11 MAST-TWO STAGE FULL FREE-LIFT

 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 11
MAST-TWO STAGE FULL FREE-LIFT

DESCRIPTION PAGE

AUXILIARY TUBE EXTENSIONS

TWO STAGE FULL FREE- LIFT - WITHOUT QUICK DISCONNECT FITTINGS (S/N B590V01652G →)
(S/N B591V01652G →) .............................................................................................................................. 11-34
TWO STAGE FULL FREE- LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B590V01652G →) (S/N B591V01652G →) ..................................................................... 11-36
TWO STAGE FULL FREE- LIFT - E-HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B590V01652G →) (S/N B591V01652G →) ..................................................................... 11-38
TWO STAGE FULL FREE-LIFT - THREE FUNCTION (→ S/N B590V01651G) (→ S/N B591V01651G)
.................................................................................................................................................................... 11-32
CARRIAGE
TWO STAGE FULL FREE-LIFT - S80-120FT ............................................................................................. 11-30
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT - S80-120FT (→ 6/2009) ......................................................................... 11-18
TWO STAGE FULL FREE-LIFT - S80-120FT (6/2009 →) ......................................................................... 11-22
HEADER HOSE
TWO STAGE FULL FREE-LIFT - S80-120FT ............................................................................................. 11-26
INNER MAST AND FREE-LIFT
TWO STAGE FULL FREE-LIFT - S80-120FT (→ 6/2009) ......................................................................... 11-6
TWO STAGE FULL FREE-LIFT - S80-120FT (6/2009 →) ......................................................................... 11-10
MAIN LIFT CYLINDER
TWO STAGE FULL FREE-LIFT - S80-120FT ............................................................................................. 11-14
OUTER MAST AND MAIN LIFT
TWO STAGE FULL FREE-LIFT - S80-120FT ............................................................................................. 11-2

©2011 HYSTER COMPANY See Service Manual 11-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

OUTER MAST AND MAIN LIFT (FIGURE 11-1)

TWO STAGE FULL FREE-LIFT — S80-120FT

11-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

OUTER MAST AND MAIN LIFT

TWO STAGE FULL FREE-LIFT – S80-120FT
B590

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm
ITEM 1 2 3 4 (119.1 in.)
Mast B590
Group Number 3025
Mast Assy 2078243
1 Outer Mast 1541455
32 Tube Assy 2072835

B591

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2765 mm 3365 mm
ITEM 1 2 3 4 (108.9 in.) (132.5 in.)
Mast B591 B591
Group Number 2765 3365
Mast Assy 2078273 2078279
1 Outer Mast 1541455 1541461
32 Tube Assy 2072835 2072841

ITEM PART NO. DESCRIPTION QTY

b. . . . . Mast Assy ........................................................................................................... 1
1 b. . . . . Outer Mast ...................................................................................................... 1
2 1500744 Stubshaft ................................................................................................... 4
3 1581588 Capscrew .................................................................................................. 4
4 1581558 Washer ...................................................................................................... 4
5 332061 Washer ...................................................................................................... 2
6 142247 Shim .......................................................................................................... AR
7 304523 Snap Ring ................................................................................................. 2
8 1325120 Shim .......................................................................................................... AR
9 ..... Main Cylinder (LH) (FFigure 11-4)......................................................... 1
10 ..... Main Cylinder (RH) (FFigure 11-4)......................................................... 1
11 1502810 Bracket ....................................................................................................... 1
12 1487068 Fitting ........................................................................................................ 1
12 16484 O-Ring ................................................................................................... 1
12 252729 O-Ring ................................................................................................... 1
13 1474399 Bracket Wldmt .......................................................................................... 1
14 14603 Plug ............................................................................................................ 1
14 16486 O-Ring ................................................................................................... 1
15 14595 Plug Assembly ......................................................................................... 1
15 16484 O-Ring ................................................................................................... 1
16 1477559 Bracket ....................................................................................................... 1
17 1581583 Capscrew .................................................................................................. 2
18 1581585 Capscrew .................................................................................................. 4
19 1581558 Washer ...................................................................................................... 4
20 1388019 Housing ..................................................................................................... 1
©2011 HYSTER COMPANY See Service Manual 11-3
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

OUTER MAST AND MAIN LIFT

TWO STAGE FULL FREE-LIFT – S80-120FT

ITEM PART NO. DESCRIPTION QTY

20 1581566 Nut ............................................................................................................. 2
21 1550197 Lowering Control Valve (S80FT) ................................................................ 1
21 1550198 Lowering Control Valve (S100-120FT) .................................................... 1
21 16982 O-Ring ................................................................................................... 1
21 280154 O-Ring ................................................................................................... 1
22 1550239 Hose Assy .................................................................................................. 1
22 1581566 Nut ............................................................................................................. 4
23 2075534
4604939 Hose Assy .................................................................................................. 1
24 1486749 Fitting ........................................................................................................ 1
24 16485 O-Ring ................................................................................................... 1
25 1550437 Bracket (LH) .............................................................................................. 1
26 1487096 Fitting ........................................................................................................ 1
27 1550439 Bracket (RH) ............................................................................................. 1
28 1581580 Capscrew ................................................................................................... 1
29 1581566 Nut ............................................................................................................. 2
30 178119 Clamp ......................................................................................................... 2
31 1550199 Fitting ......................................................................................................... 1
31 244167 O-Ring ................................................................................................... 1
31 16982 O-Ring ................................................................................................... 1
32 b. . . . . Tube Assy .................................................................................................. 1
33 1465072 Snap Ring ................................................................................................. 4
34 126765 Shim .......................................................................................................... 24
35 c 1399203 Load Roller ("A") (126.75/126.49) .................................................................. 2
35 1399204 Load Roller ("B") (127.51/127.25) ........................................................... 4
35 1399205 Load Roller ("C") (128.27/128.01) .................................................................. 2
36 104264 Wear Strip ................................................................................................. 2
37 104506 O-Ring ....................................................................................................... 4
38 161273 Shim (0.020 in.) ......................................................................................... AR
39 161272 Shim (0.007 in.) ......................................................................................... AR
40 1474354 Cap ................................................................................................................. 2
41 296430 Washer .......................................................................................................... 4
42 292591 Capscrew ...................................................................................................... 4
43 1507004 Bushing ......................................................................................................... 4
44 16002 Grease Fitting ............................................................................................... 2
45 1646820 Plug ................................................................................................................ 2
46 1646821 Plug ................................................................................................................ 2
a 192429 Bushing ......................................................................................................... 2

FOOTNOTES:
a Not Illustrated c Replace with larger depending on wear
b Refer to Table

11-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 11-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INNER MAST AND FREE-LIFT (FIGURE 11-2)

TWO STAGE FULL FREE-LIFT — S80-120FT (→ 6/2009)

11-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INNER MAST AND FREE-LIFT

TWO STAGE FULL FREE-LIFT – S80-120FT (→ 6/2009)
B590

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm
ITEM 1 2 3 4 (119.1 in.)
Mast B590
Group Number 3025
Mast Assy 2078243
1 Inner Mast 1550201
29 Chain 320395

B591

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2765 mm 3365 mm
ITEM 1 2 3 4 (108.9 in.) (132.5 in.)
Mast B591 B591
Group Number 2765 3365
Mast Assy 2078273 2078279
1 Inner Mast 1550201 1550207
29 Chain 320714 297640

ITEM PART NO. DESCRIPTION QTY

a. . . . . Mast Assy ........................................................................................................... 1
1 a. . . . . Inner Mast ...................................................................................................... 1
2 1500744 Stubshaft ................................................................................................... 4
3 1581566 Nut ................................................................................................................. 3
4 1581580 Capscrew ....................................................................................................... 1
5 1639154 Capscrew ...................................................................................................... 2
6 1581582 Capscrew ....................................................................................................... 1
7 1550193 Hyd Velocity Fuse (S80FT) ............................................................................ 1
7 1550194 Hyd Velocity Fuse (100-120FT) ..................................................................... 1
8 1465072 Snap Ring ...................................................................................................... 4
9 126765 Shim ............................................................................................................... 24
10 b 1399203 Load Roller ("A") (126.75/126.49) .................................................................. 4
10 1399204 Load Roller ("B") (127.51/127.25) ................................................................ 4
10 1399205 Load Roller ("C") (128.27/128.01) .................................................................. 4
11 297649 Ring ............................................................................................................... 2
12 2088451 Bracket (S100-120FT) ................................................................................... 2
12 2088450 Bracket (S80FT) ............................................................................................. 2
13 161003 Nut ................................................................................................................. 2
14 304527 Snap Ring ...................................................................................................... 2
15 302472 Roll Pin .......................................................................................................... 2
16 1581559 Washer .......................................................................................................... 2
17 1581564 Lockwasher ................................................................................................... 2
18 1581589 Capscrew ...................................................................................................... 2
19 1387519 Guard ............................................................................................................. 2
20 1387743 Chain Sheave ................................................................................................ 2
©2011 HYSTER COMPANY See Service Manual 11-7
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INNER MAST AND FREE-LIFT

TWO STAGE FULL FREE-LIFT – S80-120FT (→ 6/2009)

ITEM PART NO. DESCRIPTION QTY

21 ..... Lift Cylinder (FFigure 11-5)........................................................................ 1
22 c 1573177 Crosshead ...................................................................................................... 1
22 d 1389825 Crosshead (Alternate Part) .......................................................................... 1
23 1597456 Capscrew ....................................................................................................... 1
24 310549 Pin .................................................................................................................. 1
25 1581896 Nut ................................................................................................................. 4
26 15222 Cotter Pin ...................................................................................................... 2
27 1331991 Chain Anchor ................................................................................................ 2
28 339932 Pin .................................................................................................................. 2
29 a. . . . . Chain ............................................................................................................. 2

FOOTNOTES:
a Refer to Table c → 6/2008
b Replace with larger depending on wear d 6/2008 →

11-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 11-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INNER MAST AND FREE-LIFT (FIGURE 11-3)

TWO STAGE FULL FREE-LIFT — S80-120FT (6/2009 →)

11-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INNER MAST AND FREE-LIFT

TWO STAGE FULL FREE-LIFT – S80-120FT (6/2009 →)
B590

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm
ITEM 1 2 3 4 (119.1 in.)
Mast B590
Group Number 3025
Mast Assy 2078243
1 Inner Mast 1550201
29 Chain 320395

B591

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2765 mm 3365 mm
ITEM 1 2 3 4 (108.9 in.) (132.5 in.)
Mast B591 B591
Group Number 2765 3365
Mast Assy 2078273 2078279
1 Inner Mast 1550201 1550207
29 Chain 320714 297640

ITEM PART NO. DESCRIPTION QTY

a. . . . . Mast Assy ........................................................................................................... 1
1 a. . . . . Inner Mast ...................................................................................................... 1
2 1500744 Stubshaft ................................................................................................... 4
3 1581566 Nut ................................................................................................................. 1
4 1581582 Capscrew ....................................................................................................... 1
5 221628 Capscrew ....................................................................................................... 2
6 1465072 Snap Ring ...................................................................................................... 4
7 126765 Shim ............................................................................................................... 24
8 1399203 Load Roller ("A") (126.75/126.49) .................................................................. 2
8 1399204 Load Roller ("B") (127.51/127.25) ................................................................ 4
8 1399205 Load Roller ("C") (128.27/128.01) .................................................................. 2
9 1550193 Hyd Velocity Fuse (S80FT) ............................................................................ 1
9 1550194 Hyd Velocity Fuse (100-120FT) ..................................................................... 1
10 161003 Nut ................................................................................................................. 2
11 297649 Ring ............................................................................................................... 2
12 ..... Lift Cylinder (FFigure 11-5)........................................................................ 1
13 1611061 Collar .............................................................................................................. 1
14 1694479 Clamp ............................................................................................................. 1
15 1389825 Crosshead ..................................................................................................... 1
16 302493 Roll Pin .......................................................................................................... 1
17 1387281 Pin .................................................................................................................. 1
18 1387743 Chain Sheave ................................................................................................ 2
19 304527 Snap Ring ...................................................................................................... 2
20 302472 Roll Pin .......................................................................................................... 2
21 1387519 Guard ............................................................................................................. 2
©2011 HYSTER COMPANY See Service Manual 11-11
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INNER MAST AND FREE-LIFT

TWO STAGE FULL FREE-LIFT – S80-120FT (6/2009 →)

ITEM PART NO. DESCRIPTION QTY

22 1581564 Lockwasher ................................................................................................... 2
23 1581589 Capscrew ...................................................................................................... 2
25 1581896 Nut ................................................................................................................. 4
26 15222 Cotter Pin ...................................................................................................... 2
27 1331991 Chain Anchor ................................................................................................ 2
28 339932 Pin .................................................................................................................. 2
29 a. . . . . Chain ............................................................................................................. 2

FOOTNOTES:
a Refer to Table

11-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 11-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MAIN LIFT CYLINDER (FIGURE 11-4)

TWO STAGE FULL FREE-LIFT — S80-120FT

11-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MAIN LIFT CYLINDER

TWO STAGE FULL FREE-LIFT – S80-120FT
LEFT HAND

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm
1 2 3 4 (119.1 in.)
ITEM Mast B590
Group Number 3025
Cylinder
8503251
Group Number
Cylinder Assy 2073992
1 Tube Wldmt- 2074022
Cylinder
8 Cylinder Rod 1400551

RIGHT HAND

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm
1 2 3 4 (119.1 in.)
ITEM Mast B590
Group Number 3025
Cylinder
8503201
Group Number
Cylinder Assy 2073953
1 Tube Wldmt- 2074022
Cylinder
8 Cylinder Rod 1400501

LEFT HAND

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm 2765 mm
1 2 3 4 (119.1 in.) (108.9 in.)
ITEM Mast B591 B591
Group Number 2765 3365
Cylinder
8503351 8503357
Group Number
Cylinder Assy 2074126 2074138
1 Tube Wldmt- 2074022 2074042
Cylinder
8 Cylinder Rod 1400851 1400857

©2011 HYSTER COMPANY See Service Manual 11-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MAIN LIFT CYLINDER

TWO STAGE FULL FREE-LIFT – S80-120FT
RIGHT HAND

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm 2765 mm
1 2 3 4 (119.1 in.) (108.9 in.)
ITEM Mast B591 B591
Group Number 2765 3365
Cylinder
8503301 8503307
Group Number
Cylinder Assy 2074087 2074093
1 Tube Wldmt- 2074022 2074042
Cylinder
8 Cylinder Rod 1400801 1400807

ITEM PART NO. DESCRIPTION QTY

d. . . . . Cylinder Assy ...................................................................................................... 1
1 d. . . . . Tube Wldmt-Cylinder ...................................................................................... 1
2 190887 Sealing Ring ................................................................................................... 1
3 295649 Screw ............................................................................................................. 1
4 1379063 Piston Ring (RH) ............................................................................................ 1
5 1381056 Piston (RH) ..................................................................................................... 1
5 1381055 Piston (LH) ..................................................................................................... 1
6 264134 Loctite ............................................................................................................. 1
7 2038675 Wear Ring ...................................................................................................... 1
8 d. . . . . Cylinder Rod ................................................................................................... 1
9 a 1310370 Rod Wiper ...................................................................................................... 1
9 1310371 Rod Wiper ...................................................................................................... 1
10 a 1381084 Rod Seal ......................................................................................................... 1
10 1381086 Rod Seal ......................................................................................................... 1
11 a 2033295 Gland .............................................................................................................. 1
11 2033296 Gland .............................................................................................................. 1
12 198518 O-Ring ............................................................................................................ 1
13 166659 Back-Up Ring ................................................................................................. 1
14 b 357626 Spacer ............................................................................................................ 1
15 c 2094192 Sleeve (Alternate Part) ....................................................................................... 1
b 2038679 Kit-Seal (Includes Items 2, 7, 9-10, 12-13) ......................................................... 1
a 2038676 Kit-Seal (Includes Items 2, 7, 9-10, 12-13) ......................................................... 1
2104947 Kit-Seal (Alternate Part) (Includes Items 7, 9-10, 12-13, 15) .............................. 1

FOOTNOTES:
a B590 c Not Illustrated
b B591 d Refer to Table

11-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 11-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FREE-LIFT CYLINDER (FIGURE 11-5)

TWO STAGE FULL FREE-LIFT — S80-120FT (→ 6/2009)

11-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT – S80-120FT (→ 6/2009)
5/2008 AND UP

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm
1 2 3 4 (119.1 in.)
ITEM Mast B590
Group Number 3025
Cylinder
8544051
Group Number
Cylinder Assy 2104542
1 Tube Wldmt- 2073257
Cylinder
2 Cylinder Rod 2037833

UP TO 5/2008

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm
1 2 3 4 (119.1 in.)
ITEM Mast B590
Group Number 3025
Cylinder
8501701
Group Number
Cylinder Assy 2073395
1 Tube Wldmt- 2073257
Cylinder
2 Cylinder Rod 2073223

5/2008 AND UP

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm 2765 mm
1 2 3 4 (119.1 in.) (108.9 in.)
ITEM Mast B591 B591
Group Number 2765 3365
Cylinder
8518451 8518457
Group Number
Cylinder Assy 2104508 2104514
1 Tube Wldmt- 2073626 2073634
Cylinder
2 Cylinder Rod 2062074 2062079

©2011 HYSTER COMPANY See Service Manual 11-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT – S80-120FT (→ 6/2009)
UP TO 5/2008

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm 2765 mm
1 2 3 4 (119.1 in.) (108.9 in.)
ITEM Mast B591 B591
Group Number 2765 3365
Cylinder
8527801 8527807
Group Number
Cylinder Assy 2073553 2073570
1 Tube Wldmt- 2073626 2073634
Cylinder
2 Cylinder Rod 2073681 2073687

ITEM PART NO. DESCRIPTION QTY

a. . . . . Cylinder Assy .................................................................................................... 1
1 a. . . . . Tube Wldmt-Cylinder ................................................................................... 1
2 a. . . . . Cylinder Rod ................................................................................................. 1
3 2036282 Gland (S80FT) ................................................................................................ 1
3 1541640 Gland (S100-120FT) ...................................................................................... 1
4 1361302 Screw ............................................................................................................. 1
5 257913 Check Valve ................................................................................................... 1
6 297531 Washer .......................................................................................................... 1
7 187388 Snap Ring ...................................................................................................... 1
8 1383070 Rod Wiper ..................................................................................................... 1
9 637161 Rod Seal ......................................................................................................... 1
9 2033395 Seal (Alternate Part) ......................................................................................... 1
10 164632 Back-Up Ring (S80FT) ................................................................................... 1
10 615145 Back-Up Ring (S100-120FT) ........................................................................ 1
11 46629 O-Ring (S80FT) .............................................................................................. 1
11 15885 O-Ring (S100-120FT) .................................................................................... 1
12 636950 Wear Ring (S80FT) ........................................................................................ 1
12 1380982 Wear Ring (S100-120FT) .............................................................................. 1
13 637162 Rod Seal (S80FT) .......................................................................................... 1
13 364059 Rod Seal (S100-120FT) ................................................................................. 1
14 638293 Back-Up Ring (S80FT) ................................................................................... 1
14 1381074 Back-Up Ring (S100-120FT) ........................................................................ 1
15 39348 O-Ring (S80FT) .............................................................................................. 1
15 190580 O-Ring (S100-120FT) .................................................................................... 1
16 190887 Sealing Ring .................................................................................................. 1
17 1550193 Hyd Velocity Fuse (S80FT) (B590-3025 Only) ................................................... 1
17 1550194 Hyd Velocity Fuse (S100-120FT) ....................................................................... 1
2036279 Kit-Seal (S80FT) (Includes Items 8-16) .............................................................. 1
2065889 Kit-Seal (S100-120FT) (Includes Items 8-12, 14-16) ....................................... 1

FOOTNOTES:
a Refer to Table

11-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 11-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FREE-LIFT CYLINDER (FIGURE 11-6)

TWO STAGE FULL FREE-LIFT — S80-120FT (6/2009 →)

11-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT – S80-120FT (6/2009 →)
B590

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm
1 2 3 4 (119.1 in.)
ITEM Mast B590
Group Number 3025
Cylinder
8544051
Group Number
Cylinder Assy 2104542
1 Tube Wldmt- 2073257
Cylinder
2 Cylinder Rod 2037833

B591

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2765 mm 3365 mm
1 2 3 4 (108.9 in.) (132.5 in.)
ITEM Mast B591 B591
Group Number 2765 3365
Cylinder
8518451 8518457
Group Number
Cylinder Assy 2104508 2104514
1 Tube Wldmt- 2073626 2073634
Cylinder
2 Cylinder Rod 2062074 2062079

ITEM PART NO. DESCRIPTION QTY

a. . . . . Cylinder Assy .................................................................................................... 1
1 a. . . . . Tube Wldmt-Cylinder ................................................................................... 1
2 a. . . . . Cylinder Rod ................................................................................................. 1
3 2036282 Gland (S80FT) ................................................................................................ 1
3 1541640 Gland (S100-120FT) ...................................................................................... 1
4 1361302 Screw ............................................................................................................. 1
5 297538 Check Valve .................................................................................................. 1
6 297531 Washer .......................................................................................................... 1
7 187388 Snap Ring ...................................................................................................... 1
8 1383070 Rod Wiper ..................................................................................................... 1
9 637161 Rod Seal ......................................................................................................... 1
10 164632 Back-Up Ring (S80FT) ................................................................................... 1
10 615145 Back-Up Ring (S100-120FT) ........................................................................ 1
11 46629 O-Ring (S80FT) .............................................................................................. 1
11 15885 O-Ring (S100-120FT) .................................................................................... 1
12 636950 Wear Ring (S80FT) ........................................................................................ 1
12 1380982 Wear Ring (S100-120FT) .............................................................................. 1
13 637162 Rod Seal (S80FT) .......................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 11-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT – S80-120FT (6/2009 →)

ITEM PART NO. DESCRIPTION QTY

13 364059 Rod Seal (S100-120FT) ................................................................................. 1
14 638293 Back-Up Ring (S80FT) ................................................................................... 1
14 1381074 Back-Up Ring (S100-120FT) ........................................................................ 1
15 39348 O-Ring (S80FT) .............................................................................................. 1
15 190580 O-Ring (S100-120FT) .................................................................................... 1
16 190887 Sealing Ring .................................................................................................. 1
2036279 Kit-Seal (S80FT) (Includes Items 8-16) .............................................................. 1
2065889 Kit-Seal (S100-120FT) (Includes Items 8-12, 14-16) ....................................... 1

FOOTNOTES:
a Refer to Table

11-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 11-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HEADER HOSE (FIGURE 11-7)

TWO STAGE FULL FREE-LIFT — S80-120FT

11-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HEADER HOSE
TWO STAGE FULL FREE-LIFT – S80-120FT
B590

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3025 mm
ITEM 1 2 3 4 (119.1 in.)
Mast B590
Group Number 3025
Mast Assy 2078243
1 Hose Assy 2078589
2 Hose Assy 2078625
3 Channel 1550391
4 Channel 1611928
5 Hose Assy 2078655
7 Hose Assy 2077914
8 Hose Assy 2078050

B591

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2765 mm 3365 mm
ITEM 1 2 3 4 (108.9 in.) (132.5 in.)
Mast B591 B591
Group Number 2765 3365
Mast Assy 2078273 2078279
1 Hose Assy 2078585 2078591
2 Hose Assy 2078625 2078631
3 Channel 1550391 1550397
4 Channel 1611925 1611931
5 Hose Assy 2078685 2078691
7 Hose Assy 2077914 2077914
8 Hose Assy 2078050 2078056

KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
a. . . . . Mast Assy .......................................................................................... 1 1 1
1 a. . . . . Hose Assy ..................................................................................... 2 2 2
2 a. . . . . Hose Assy ..................................................................................... 2 2 2
3 a. . . . . Channel ......................................................................................... 1 1 1
4 a. . . . . Channel ......................................................................................... 1 1 1

©2011 HYSTER COMPANY See Service Manual 11-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HEADER HOSE
TWO STAGE FULL FREE-LIFT – S80-120FT
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
5 a. . . . . Hose Assy ..................................................................................... 2 2 2
6 2085076 Hose Assy ..................................................................................... .. 2 2
7 a. . . . . Hose Assy ..................................................................................... .. 2 2
8 a. . . . . Hose Assy ..................................................................................... .. .. 2
9 1360507 Clamp ............................................................................................ 2 2 2
10 1654323 Capscrew ...................................................................................... 2 2 2
11 1541242 Bracket Wldmt ............................................................................... 1 1 1
12 1581560 Washer .......................................................................................... 1 1 1
13 1495279 Hose Sheave ................................................................................. 1 1 1
13 332057 Bushing ..................................................................................... 1 1 1
14 58902 Snap Ring ..................................................................................... 1 1 1
15 302472 Roll Pin .......................................................................................... 1 1 1
16 2079377 Tube Assy ..................................................................................... 1 1 1
17 2079376 Tube Assy ..................................................................................... 1 1 1
18 1360529 Clamp ............................................................................................ 2 2 2
19 2035791 Hose Clamp .................................................................................. 2 2 2
20 1581741 Capscrew ...................................................................................... 2 2 2
21 1502809 Hose Clamp .................................................................................. 1 1 1
22 1399323 Pad ................................................................................................ 2 2 2
23 1397682 Clamp ............................................................................................ 2 2 2
24 1581556 Washer .......................................................................................... 3 3 3
25 1581562 Lockwasher ................................................................................... 3 3 3
26 1581582 Capscrew ...................................................................................... 2 2 2
27 1581594 Capscrew ...................................................................................... 1 1 1
28 1550425 Fitting ............................................................................................ 1 1 1
29 358286 Strain Relief ................................................................................... .. 1 1
30 358287 Bracket .......................................................................................... .. 1 1
31 16870 Capscrew ...................................................................................... .. 2 2
31 bc 1597442 Capscrew (With Side-Shift) (Alternate Part) .................................. .. .. 2
31 de 1597442 Capscrew (Without Side-Shift) ...................................................... .. .. 3
32 15156 Lockwasher ................................................................................... .. 2 2
32 de 1581563 Lockwasher (Without Side-Shift) ................................................... .. .. 4
33 358289 Hose Reel ..................................................................................... .. 1 1
33 672563 Kit-Seal ..................................................................................... .. 1 1
34 16541 Fitting ............................................................................................ .. 4 4
34 16484 O-Ring ...................................................................................... .. 1 1
35 1618437 Plate .................................................................................................. .. 1 1
36 1581594 Capscrew .......................................................................................... .. 2 2
37 1581559 Washer .............................................................................................. .. 2 2
38 bc 1597853 Plate (Without Side-Shift) .................................................................. .. 1 1
38 de 1705595 Bracket (Without Side-Shift) .............................................................. .. .. 1
38 de 136692 Nut (Without Side-Shift) ..................................................................... .. .. 1
38 1599321 Plate (With Side-Shift) ....................................................................... .. .. 1
39 1502809 Hose Clamp ....................................................................................... .. 2 2

11-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HEADER HOSE
TWO STAGE FULL FREE-LIFT – S80-120FT
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
40 1360507 Clamp ................................................................................................ .. 2 2
41 378044 Hose Reel .......................................................................................... .. .. 1
41 672563 Kit-Seal .............................................................................................. .. .. 1
42 1581849 Nut ..................................................................................................... .. 2 2
43 1550425 Fitting ................................................................................................. 1 1 1
44 1556897 Fitting (Mast Removal) ...................................................................... .. 2 2
45 1581565 Nut ..................................................................................................... 2 2 2
46 1473887 Fitting ................................................................................................. .. 2 2
47 1581590 Capscrew ...................................................................................... 1 1 1
48 2091910 Tube Assy ......................................................................................... .. 1 1
49 2091911 Tube Assy ......................................................................................... .. 1 1
50 816591 Fitting (Includes Nut) ......................................................................... .. 2 2
50 265731 O-Ring ........................................................................................... .. 2 2
50 816593 Locknut .......................................................................................... .. 1 1

FOOTNOTES:
a Refer to Table d S/N B590V01615G →
b → S/N B590V01614G e S/N B591V01631G →
c → S/N B591V01630G

©2011 HYSTER COMPANY See Service Manual 11-29

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

CARRIAGE (FIGURE 11-8)

TWO STAGE FULL FREE-LIFT — S80-120FT

11-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

CARRIAGE
TWO STAGE FULL FREE-LIFT – S80-120FT
KEY:
A: S80FT
B: S100-120FT
C: S100FT (Attachment)
QTY
ITEM PART NO. DESCRIPTION A B C
1401670 Carriage (42 in.) ................................................................................ 1 .. ..
2108024 Carriage (42 in) (Alternate Part) ........................................................ 1 .. ..
1401672 Carriage (42 in.) ................................................................................ .. 1 ..
2108034 Carriage (42 in.) (Alternate Part) ....................................................... .. 1 ..
1401674 Carriage (42 in.) ................................................................................ .. .. 1
2108026 Carriage (42 in.) (Alternate Part) ....................................................... .. .. 1
1 1401640 Carriage Wldmt (42 in.) ................................................................. 1 .. ..
1 1695566 Carriage Wldmt (42 in.) (Alternate Part) ........................................ 1 .. ..
1 1401642 Carriage Wldmt (42 in.) ................................................................. .. 1 ..
1 1692911 Carriage Wldmt (42 in.) (Alternate Part) ........................................ .. 1 ..
1 1401644 Carriage Wldmt (42 in.) ................................................................. .. .. 1
1 1695160 Carriage Wldmt (42 in.) (Alternate Part) ........................................ .. .. 1
2 1500744 Stubshaft ................................................................................... 6 6 6
3 1465177 Bracket .......................................................................................... .. .. 2
4 1387993 Side Roller ..................................................................................... .. .. 2
4 1670064 Cam Follower (Alternate Part) ....................................................... .. .. 2
5 1465028 Pin ................................................................................................. .. .. 2
5 1670065 Pin (Alternate Part) ........................................................................ .. .. 2
6 292683 Lockwasher ................................................................................... .. .. 4
7 292528 Capscrew ...................................................................................... .. .. 4
8 319323 Bracket Wldmt (LH) ....................................................................... 1 1 1
9 319322 Bracket Wldmt (RH) ...................................................................... 1 1 1
10 1624590 Chain Anchor ................................................................................ 2 2 2
11 339932 Pin ................................................................................................. 2 2 2
12 15222 Cotter Pin ...................................................................................... 2 2 2
13 1465072 Snap Ring ..................................................................................... 6 6 6
14 1399224 Spacer ........................................................................................... 2 2 2
15 126765 Shim .............................................................................................. 24 24 24
16 1511883 Load Roller ("B") (104.44/104.18) ................................................. 6 6 6
17 317292 Spacer ........................................................................................... 4 4 4
18 18518 Capscrew ...................................................................................... 4 1 4
18 18520 Capscrew ...................................................................................... .. 3 ..
19 15155 Lockwasher ................................................................................... 4 4 4
20 1624589 Pin ................................................................................................. 2 2 ..
21 131358 Snap Ring ..................................................................................... 2 2 ..
22 66333 Roll Pin .......................................................................................... .. .. 2
23 16001 Grease Fitting ................................................................................ .. .. 2
24 192425 Shim (0.062 in.) ............................................................................. .. .. AR
25 192424 Shim (0.030 in.) ............................................................................. .. .. AR

©2011 HYSTER COMPANY See Service Manual 11-31

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 11-9)

TWO STAGE FULL FREE-LIFT — THREE FUNCTION (→ S/N B590V01651G) (→ S/N B591V01651G)

11-32 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

TWO STAGE FULL FREE-LIFT – THREE FUNCTION (→ S/N B590V01651G) (→ S/N B591V01651G)

ITEM PART NO. DESCRIPTION QTY

1 1529016 Fitting .................................................................................................................. 2
1 265731 O-Ring ............................................................................................................ 1
2 1473887 Fitting .................................................................................................................. 2
2 265731 O-Ring ............................................................................................................ 1
2 16484 O-Ring ............................................................................................................ 1
3 2087565 Drain Valve ......................................................................................................... 1
4 16541 Fitting .................................................................................................................. 1
5 16484 O-Ring ............................................................................................................ 1
6 1377954 Fitting .................................................................................................................. 2
7 1377953 Quick Disconnect Fitting ..................................................................................... 2
8 1622610 Fitting .................................................................................................................. 2
8 16484 O-Ring ............................................................................................................ 1
8 265731 O-Ring ............................................................................................................ 1
9 816591 Fitting (Includes Nut) ........................................................................................... 2
10 1643341 Bracket ................................................................................................................ 1
10 1705595 Bracket (Alternate Part) ...................................................................................... 1
10 1597442 Capscrew (Alternate Part) .................................................................................. 2
10 1581563 Lockwasher (Alternate Part) ............................................................................... 4
11 2089556 Tube Assy ........................................................................................................... 1
11 2089910 Tube Assy ........................................................................................................... 1
11 b 2089563 Tube Assy ........................................................................................................... 1
12 2089557 Tube Assy ........................................................................................................... 1
12 2089911 Tube Assy ........................................................................................................... 1
12 b 2089562 Tube Assy ........................................................................................................... 1
a 181298 Dust Cap ............................................................................................................. 1
a 181266 Dust Cap ............................................................................................................. 1

FOOTNOTES:
a Not Illustrated b Used With Attachment Carriage

©2011 HYSTER COMPANY See Service Manual 11-33

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 11-10)

TWO STAGE FULL FREE- LIFT — WITHOUT QUICK DISCONNECT FITTINGS (S/N B590V01652G →)
(S/N B591V01652G →)

11-34 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

TWO STAGE FULL FREE- LIFT – WITHOUT QUICK DISCONNECT FITTINGS (S/N B590V01652G →)
(S/N B591V01652G →)
KEY:
A: B590, Three Function
B: B591, Three Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1529016 Fitting ......................................................................................................... 2 2
2 816591 Fitting (Includes Nut) .................................................................................. 2 2
3 816593 Locknut ....................................................................................................... 2 2
4 1705595 Bracket (RH) .............................................................................................. 1 1
5 1581563 Lockwasher ................................................................................................ 2 2
6 1597443 Bolt ............................................................................................................. 2 2
7 2089556 Tube Assy .................................................................................................. 1 ..
7 2088910 Tube Assy .................................................................................................. .. 1
7 a 2089562 Tube Assy .................................................................................................. .. 1
8 2089557 Tube Assy .................................................................................................. 1 ..
8 2089911 Tube Assy .................................................................................................. .. 1
8 a 2089563 Tube Assy .................................................................................................. .. 1

FOOTNOTES:
a Used with Attachment Carriage

©2011 HYSTER COMPANY See Service Manual 11-35

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 11-11)

TWO STAGE FULL FREE- LIFT — MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B590V01652G →) (S/N B591V01652G →)

11-36 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

TWO STAGE FULL FREE- LIFT – MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B590V01652G →) (S/N B591V01652G →)
KEY:
A: B590, Three Function
B: B591, Three Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1529016 Fitting ......................................................................................................... 2 2
2 1473887 Fitting ......................................................................................................... 2 2
3 1377953 Quick Disconnect Fitting ............................................................................ 2 2
4 1377954 Fitting (Quick Disconnect) .......................................................................... 2 2
5 1708368 Dust Cover ................................................................................................. 2 2
6 1708365 Bulkhead (Fitting) ....................................................................................... 2 2
7 816593 Locknut ....................................................................................................... 2 2
8 1705595 Bracket (RH) .............................................................................................. 1 1
9 1581563 Lockwasher ................................................................................................ 2 2
10 1597443 Bolt ............................................................................................................. 2 2
11 2089556 Tube Assy .................................................................................................. 1 ..
11 2089910 Tube Assy .................................................................................................. .. 1
11 a 2089562 Tube Assy .................................................................................................. .. 1
12 2089557 Tube Assy .................................................................................................. 1 ..
12 2089911 Tube Assy .................................................................................................. .. 1
12 2089563 Tube Assy .................................................................................................. .. 1

FOOTNOTES:
a Used with Attachment Carriage

©2011 HYSTER COMPANY See Service Manual 11-37

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 11-12)

TWO STAGE FULL FREE- LIFT — E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B590V01652G →) (S/N B591V01652G →)

11-38 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

TWO STAGE FULL FREE- LIFT – E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B590V01652G →) (S/N B591V01652G →)
KEY:
A: B590, Three Function
B: B591, Three Function
QTY
ITEM PART NO. DESCRIPTION A B
1 1487095 Fitting ......................................................................................................... 2 2
2 4604566 Hose Assy .................................................................................................. 1 1
3 1529016 Fitting ......................................................................................................... 2 2
4 1473887 Fitting ......................................................................................................... 2 2
5 1377953 Quick Disconnect Fitting ............................................................................ 2 2
6 1377954 Fitting (Quick Disconnect) .......................................................................... 2 2
7 1708368 Dust Cover ................................................................................................. 2 2
8 1708365 Bulkhead (Fitting) ....................................................................................... 2 2
9 1581563 Lockwasher ................................................................................................ 2 2
10 1597443 Bolt ............................................................................................................. 2 2
11 816593 Locknut ....................................................................................................... 2 2
12 1527885 Capscrew ................................................................................................... 2 2
13 2089556 Tube Assy .................................................................................................. 1 ..
13 2089910 Tube Assy .................................................................................................. .. 1
13 a 2089562 Tube Assy .................................................................................................. .. 1
14 2089557 Tube Assy .................................................................................................. 1 ..
14 2089911 Tube Assy .................................................................................................. .. 1
14 a 2089563 Tube Assy .................................................................................................. .. 1
15 1399085 Hose Assy .................................................................................................. 1 1
16 1502059 Clamp ......................................................................................................... 1 1
17 1502066 Clamp ......................................................................................................... 1 1
18 1527979 Hose Clamp ............................................................................................... 2 2
19 110178 Fitting ......................................................................................................... 2 2
19 16483 O-Ring ................................................................................................... 2 2
20 292505 Capscrew ................................................................................................... 2 2
21 1708373 Bracket ....................................................................................................... 1 1
22 2111754 Valve (Single Aux) ...................................................................................... 1 1
23 1486737 Fitting ......................................................................................................... 2 2
24 4604565 Hose Assy .................................................................................................. 1 1
25 1705595 Bracket ....................................................................................................... 1 1
26 302399 Nut .............................................................................................................. 2 2

FOOTNOTES:
a Used with Attached Carriage

©2011 HYSTER COMPANY See Service Manual 11-39

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NOTES

11-40 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

12 MAST-THREE STAGE FULL FREE-LIFT

 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 12
MAST-THREE STAGE FULL FREE-LIFT

DESCRIPTION PAGE

AUXILIARY TUBE EXTENSIONS

THREE STAGE FULL FREE-LIFT - WITHOUT QUICK DISCONNECT
FITTINGS (S/N B588V02595G →) (S/N B589V03132G →) ..................................................................... 12-40
THREE STAGE FULL FREE-LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B588V02595G →) (S/N B589V03132G →) ..................................................................... 12-42
THREE STAGE FULL FREE-LIFT - E-HYDRAULICS WITH QUICK DISCONNECT
FITTINGS (S/N B588V02595G →) (S/N B589V03132G →) ..................................................................... 12-44
THREE STAGE FULL FREE-LIFT (→ S/N B588V02594G) (→ S/N B589V03131G) ............................... 12-36
CARRIAGE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-32
FREE-LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-20
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-24
HEADER HOSE
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-28
INNER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-6
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-8
MAIN LIFT
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-12
MAIN LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-16
OUTER MAST
THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-2

©2011 HYSTER COMPANY See Service Manual 12-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

OUTER MAST (FIGURE 12-1)

THREE STAGE FULL FREE-LIFT

12-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

OUTER MAST
THREE STAGE FULL FREE-LIFT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4365 mm 4665 mm 4900 mm 5500 mm
ITEM 1 2 3 4 (171.9 in.) (183.7 in.) (192.9 in.) (216.5 in.)
Mast B588 B588 B588 B588
Group Number 4365 4665 4900 5500
Mast Assy 2078199 2078201 2078202 2078206
1 Outer Mast 1540694 1540696 1540697 1540701
14 Chain 191081 182342 194607 191072

S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4087 mm 4640 mm 5240 mm
ITEM 1 2 3 4 (160.9 in.) (182.7 in.) (206.3 in.)
Mast B589 B589 B589
Group Number 4087 4640 5240
Mast Assy 2078223 2078226 2078230
1 Outer Mast 1540694 1540697 1540701
14 Chain 280878 152404 356916

ITEM PART NO. DESCRIPTION QTY

a. . . . . Mast Assy .......................................................................................................... 1
1 a. . . . . Outer Mast ..................................................................................................... 1
2 1500744 Stubshaft ................................................................................................... 2
3 b 1399203 Load Roller ("A") (126.75/126.49) .................................................................. 2
3 1399204 Load Roller ("B") (127.51/127.25) ................................................................ 2
3 1399205 Load Roller ("C") (128.27/128.01) .................................................................. 2
4 126765 Shim ............................................................................................................... AR
5 1465072 Snap Ring ...................................................................................................... 2
6 161273 Shim (0.020 in.) ............................................................................................. AR
7 161272 Shim (0.007 in.) ............................................................................................. AR
8 104264 Wear Strip ..................................................................................................... 2
9 104506 O-Ring ........................................................................................................... 4
10 1331990 Chain Anchor (S80FT) ................................................................................... 2
10 1331991 Chain Anchor (100-120FT) ........................................................................... 2
11 327591 Pin (S80FT) .................................................................................................... 2
11 339932 Pin (S100-120FT) .......................................................................................... 2
12 15222 Cotter Pin ...................................................................................................... 2
13 221717 Nut .................................................................................................................. 4
14 a. . . . . Chain ............................................................................................................. 2
15 1474354 Cap ................................................................................................................. 2
16 296430 Washer .......................................................................................................... 4
17 292591 Capscrew ...................................................................................................... 4
18 1507004 Bushing ......................................................................................................... 4
19 16002 Grease Fitting ............................................................................................... 2
20 1646820 Plug ................................................................................................................ 2
©2011 HYSTER COMPANY See Service Manual 12-3
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

OUTER MAST
THREE STAGE FULL FREE-LIFT

ITEM PART NO. DESCRIPTION QTY

21 1646821 Plug ................................................................................................................ 2

FOOTNOTES:
a Refer to Table b Replace with larger depending on wear

12-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 12-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INNER MAST (FIGURE 12-2)

THREE STAGE FULL FREE-LIFT

12-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INNER MAST
THREE STAGE FULL FREE-LIFT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4365 mm 4665 mm 4900 mm 5500 mm
ITEM 1 2 3 4 (171.9 in.) (183.7 in.) (192.9 in.) (216.5 in.)
Mast B588 B588 B588 B588
Group Number 4365 4665 4900 5500
Mast Assy 2078199 2078201 2078202 2078206
1 Inner Mast 1573599 1573601 1573602 1573606

S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4087 mm 4640 mm 5240 mm
ITEM 1 2 3 4 (160.9 in.) (182.7 in.) (206.3 in.)
Mast B589 B589 B589
Group Number 4087 4640 5240
Mast Assy 2078223 2078226 2078230
1 Inner Mast 1573599 1573602 1573606

ITEM PART NO. DESCRIPTION QTY

a. . . . . Mast Assy .......................................................................................................... 1
1 a. . . . . Inner Mast ..................................................................................................... 1
2 1500744 Stubshaft ................................................................................................... 2
3 b 1511882 Load Roller ("A") (103.68/103.42) .................................................................. 2
3 1511883 Load Roller ("B") (104.44/104.18) ................................................................ 2
3 1511884 Load Roller ("C") (105.20/104.94) .................................................................. 2
4 126765 Shim ............................................................................................................... AR
5 1465072 Snap Ring ...................................................................................................... 2
6 1387285 Chain Anchor (S80FT) ................................................................................... 2
6 1387286 Chain Anchor (S100-120FT) ........................................................................ 2
7 327591 Pin (S80FT) .................................................................................................... 2
7 339932 Pin (S100-120FT) .......................................................................................... 2
8 15222 Cotter Pin ...................................................................................................... 2
9 1581896 Nut ................................................................................................................. 4
10 15224 Cotter Pin ...................................................................................................... 2

FOOTNOTES:
a Refer to Table b Replace with larger depending on wear

©2011 HYSTER COMPANY See Service Manual 12-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTERMEDIATE MAST (FIGURE 12-3)

THREE STAGE FULL FREE-LIFT

12-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4365 mm 4665 mm 4900 mm 5500 mm
ITEM 1 2 3 4 (171.9 in.) (183.7 in.) (192.9 in.) (216.5 in.)
Mast B588 B588 B588 B588
Group Number 4365 4665 4900 5500
Mast Assy 2078199 2078201 2078202 2078206
1 Intermediate Mast 1574162 1574164 1574165 1574169

S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4087 mm 4640 mm 5240 mm
ITEM 1 2 3 4 (160.9 in.) (182.7 in.) (206.3 in.)
Mast B589 B589 B589
Group Number 4087 4640 5240
Mast Assy 2078223 2078226 2078230
1 Intermediate Mast 1574162 1574165 1574169

ITEM PART NO. DESCRIPTION QTY

c. . . . . Mast Assy .......................................................................................................... 1
1 c. . . . . Intermediate Mast ......................................................................................... 1
2 1500744 Stubshaft ................................................................................................... 4
3 d 1399203 Load Roller ("A") (126.75/126.49) .................................................................. 2
3 1399204 Load Roller ("B") (127.51/127.25) ................................................................ 2
3 1399205 Load Roller ("C") (128.27/128.01) .................................................................. 2
4 d 1511882 Load Roller ("A") (103.68/103.42) .................................................................. 2
4 1511883 Load Roller ("B") (104.44/104.18) ................................................................ 2
4 1511884 Load Roller ("C") (105.20/104.94) .................................................................. 2
5 126765 Shim ............................................................................................................... 24
6 1465072 Snap Ring ...................................................................................................... 4
7 131716 Shim (0.020 in.) ............................................................................................. AR
8 131715 Shim (0.007 in.) ............................................................................................. AR
9 215211 Wear Strip ..................................................................................................... 2
10 104506 O-Ring ........................................................................................................... 4
11 1389846 Spacer ........................................................................................................... 2
12 1389780 Chain Sheave (S80FT) ................................................................................... 2
12 1389779 Chain Sheave (100-120FT) ........................................................................... 2
12 1389673 Chain Sheave (S80FT) .............................................................................. 1
12 1389672 Chain Sheave (S100-120FT) .................................................................... 1
12 40667 Snap Ring .................................................................................................. 1
12 126764 Load Roller ............................................................................................... 1
13 12891 Snap Ring ...................................................................................................... 2
14 b 1389959 Bracket ........................................................................................................... 1
15 b 1581564 Lockwasher ................................................................................................... 1
16 b 1581559 Washer .......................................................................................................... 1
17 b 1581590 Capscrew ...................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 12-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT

ITEM PART NO. DESCRIPTION QTY

18 1389932 Stubshaft ....................................................................................................... 2
a 1466633 Insert .............................................................................................................. 4

FOOTNOTES:
a Not Illustrated c Refer to Table
b Not used on all applications d Replace with larger depending on wear

12-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 12-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MAIN LIFT (FIGURE 12-4)

THREE STAGE FULL FREE-LIFT

12-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MAIN LIFT
THREE STAGE FULL FREE-LIFT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4365 mm 4665 mm 4900 mm 5500 mm
ITEM 1 2 3 4 (171.9 in.) (183.7 in.) (192.9 in.) (216.5 in.)
Mast B588 B588 B588 B588
Group Number 4365 4665 4900 5500
18 Hose Assy 1399080 1399084 1399088 1399096
19 Hose Assy 1399096 1399100 1399104 1399112

S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4087 mm 4640 mm 5240 mm
ITEM 1 2 3 4 (160.9 in.) (182.7 in.) (206.3 in.)
Mast B589 B589 B589
Group Number 4087 4640 5240
18 Hose Assy 1399080 1399088 1399096
19 Hose Assy 1399096 1399104 1399112

ITEM PART NO. DESCRIPTION QTY

1 ..... Main Cylinder (FFigure 12-5)...................................................................... 2
2 c 1550195 Hyd Velocity Fuse (Free-Lift Cylinder) (12 x 16) ............................................ 1
2 c 1550157 Hyd Velocity Fuse (10 x 10) ........................................................................... 2
2 b 1550196 Hyd Velocity Fuse (Free-Lift Cylinder) (12 x 16) ........................................ 1
2 b 1550158 Hyd Velocity Fuse (10 x 10) ......................................................................... 2
3 110178 Fitting ............................................................................................................ 2
3 16483 O-Ring ....................................................................................................... 1
4 304523 Snap Ring ...................................................................................................... 2
5 1325120 Shim ............................................................................................................... AR
6 142247 Shim ............................................................................................................... AR
7 332061 Washer .......................................................................................................... 2
8 1550437 Bracket (LH) .................................................................................................. 1
8 1550439 Bracket (RH) .................................................................................................. 1
9 1581563 Lockwasher ................................................................................................... 4
10 1581585 Capscrew ...................................................................................................... 5
11 1474496 Bracket (RH) .................................................................................................. 1
11 1474497 Bracket (LH) .................................................................................................. 1
12 1581558 Washer .......................................................................................................... 4
13 1581588 Capscrew ...................................................................................................... 4
14 379405 Clamp ............................................................................................................ 4
15 2046871 Fitting ............................................................................................................ 1
16 1465585 Hose Clamp ................................................................................................... 4
17 1360529 Clamp ............................................................................................................ 4
18 a. . . . . Hose Assy ..................................................................................................... 1
19 a. . . . . Hose Assy ..................................................................................................... 1
20 1487068 Fitting ............................................................................................................ 1
20 16484 O-Ring ....................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 12-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MAIN LIFT
THREE STAGE FULL FREE-LIFT

ITEM PART NO. DESCRIPTION QTY

20 252729 O-Ring ....................................................................................................... 1
21 16543 Connector ....................................................................................................... 1
21 16486 O-Ring ....................................................................................................... 1
22 1388019 Housing ......................................................................................................... 1
23 14595 Plug Assembly .............................................................................................. 1
23 16484 O-Ring ....................................................................................................... 1
24 1474387 Bracket .......................................................................................................... 1
25 1550197 Lowering Control Valve (S80FT) .................................................................... 1
25 1550198 Lowering Control Valve (S100-120FT) ........................................................ 1
26 2074180 Hose Assy ..................................................................................................... 1
27 1487096 Fitting ............................................................................................................ 1
28 2074181
4604938 Hose Assy ..................................................................................................... 1

FOOTNOTES:
a Refer to Table c S80FT
b S100-120FT

12-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 12-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MAIN LIFT CYLINDER (FIGURE 12-5)

THREE STAGE FULL FREE-LIFT

12-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MAIN LIFT CYLINDER

THREE STAGE FULL FREE-LIFT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4365 mm 4665 mm 4900 mm 5500 mm
1 2 3 4 (171.9 in.) (183.7 in.) (192.9 in.) (216.5 in.)
ITEM Mast B588 B588 B588 B588
Group Number 4365 4665 4900 5500
Cylinder
8509701 8509703 8509704 8509708
Group Number
Cylinder Assy 2073852 2073854 2073857 2073859
1 Tube Wldmt- 2073888 2073890 2073891 2073895
Cylinder
2 Cylinder Rod 2037856 2037857 2037858 2037860

S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4087 mm 4640 mm 5240 mm
1 2 3 4 (160.9 in.) (182.7 in.) (206.3 in.)
ITEM Mast B589 B589 B589
Group Number 4087 4640 5240
Cylinder
8509801 8509804 8509808
Group Number
Cylinder Assy 2073912 2073915 2073919
1 Tube Wldmt- 2073932 2073935 2073939
Cylinder
2 Cylinder Rod 2037841 2037844 2037846

KEY:
A: S80FT
B: S100-120FT
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ........................................................................................... 2 2
1 a. . . . . Tube Wldmt-Cylinder ........................................................................... 1 1
2 a. . . . . Cylinder Rod ........................................................................................ 1 1
3 2033243 Gland ..................................................................................................... 1 ..
3 2033299 Gland ..................................................................................................... .. 1
4 215425 Wear Ring .............................................................................................. 1 ..
4 215301 Wear Ring ............................................................................................. .. 1
5 1383066 Rod Wiper .............................................................................................. 1 ..
5 1383068 Rod Wiper ............................................................................................. .. 1
6 270077 Rod Seal ................................................................................................ 1 ..
6 201829 Rod Seal ............................................................................................... .. 1

©2011 HYSTER COMPANY See Service Manual 12-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MAIN LIFT CYLINDER

THREE STAGE FULL FREE-LIFT
KEY:
A: S80FT
B: S100-120FT
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
7 638249 Back-Up Ring ......................................................................................... 2 ..
7 638250 Back-Up Ring ....................................................................................... .. 1
8 57664 O-Ring ................................................................................................... 1 ..
8 15879 O-Ring ................................................................................................... .. 1
9 297532 Wear Ring .............................................................................................. 1 ..
9 351531 Wear Ring ............................................................................................. .. 1
10 1381061 Rod Seal ................................................................................................ 1 ..
10 1381062 Rod Seal ............................................................................................... .. 1
11 1379063 Piston Ring (RH) .................................................................................... 1 ..
11 2036479 Piston Ring ........................................................................................... .. 1
12 351532 Back-Up Ring ....................................................................................... .. 1
14 2036277 Kit-Seal (Includes Items 4-10) .................................................................... 1 ..
14 2036278 Kit-Seal (Includes Items 4-10, 12) ........................................................... .. 1

FOOTNOTES:
a Refer to Table

12-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 12-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FREE-LIFT (FIGURE 12-6)

THREE STAGE FULL FREE-LIFT

12-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FREE-LIFT
THREE STAGE FULL FREE-LIFT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4365 mm 4665 mm 4900 mm 5500 mm
ITEM 1 2 3 4 (171.9 in.) (183.7 in.) (192.9 in.) (216.5 in.)
Mast B588 B588 B588 B588
Group Number 4365 4665 4900 5500
27 Chain 320395 386885 297640 337189
31 Hose Assy 2072865 2072867 2072868 2072872

S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4087 mm 4640 mm 5240 mm
ITEM 1 2 3 4 (160.9 in.) (182.7 in.) (206.3 in.)
Mast B589 B589 B589
Group Number 4087 4640 5240
27 Chain 320714 386885 337180
31 Hose Assy 2072865 2072868 2072872

ITEM PART NO. DESCRIPTION QTY

1 2036778 Hose Sheave ................................................................................................. 1
2 1387553 Stubshaft ........................................................................................................ 1
3 1581564 Lockwasher ................................................................................................... 4
4 1581559 Washer .......................................................................................................... 4
5 1581592 Capscrew ...................................................................................................... 1
6 1639154 Capscrew ...................................................................................................... 2
7 1387479 Hose Clamp ................................................................................................... 1
8 1581565 Nut ................................................................................................................. 2
9 1581578 Capscrew ...................................................................................................... 2
10 1550195 Hyd Velocity Fuse (Free-Lift Cylinder) (S80FT) ............................................. 1
10 1550196 Hyd Velocity Fuse (Free-Lift Cylinder) (S100-120FT) ................................ 1
11 ..... Free-Lift Cylinder (FFigure 12-7)................................................................ 1
12 310549 Pin .................................................................................................................. 1
13 e 1573177 Crosshead ...................................................................................................... 1
13 f 1389825 Crosshead (Alternate Part) .......................................................................... 1
14 1581559 Washer .......................................................................................................... 4
15 1597456 Capscrew ....................................................................................................... 1
16 1387519 Guard ............................................................................................................. 2
17 302472 Roll Pin .......................................................................................................... 4
18 1581589 Capscrew ...................................................................................................... 2
19 1387743 Chain Sheave ................................................................................................ 2
19 1387740 Chain Sheave ............................................................................................ 1
20 126764 Load Roller ............................................................................................... 1
21 40667 Snap Ring .................................................................................................. 2
22 304527 Snap Ring ...................................................................................................... 2
23 c 2088451 Bracket .......................................................................................................... 2
23 c 1694480 Clamp (Alternate Part) .................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 12-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FREE-LIFT
THREE STAGE FULL FREE-LIFT

ITEM PART NO. DESCRIPTION QTY

23 d 2088450 Bracket ........................................................................................................... 2
23 d 1694479 Clamp (Alternate Part) .................................................................................... 1
24 161003 Nut ................................................................................................................. 2
25 297649 Ring ............................................................................................................... 2
26 1581896 Nut ................................................................................................................. 4
27 b. . . . . Chain ............................................................................................................. 2
28 1331991 Chain Anchor ................................................................................................ 2
29 15222 Cotter Pin ...................................................................................................... 2
30 339932 Pin .................................................................................................................. 2
31 b. . . . . Hose Assy ..................................................................................................... 1
32 1611061 Collar (S80FT) ................................................................................................ 1
33 1626490 Washer .......................................................................................................... 2
a 1638844 Shim (Cylinder Clamp) ................................................................................. AR

FOOTNOTES:
a Not Illustrated d S80FT
b Refer to Table e → 6/2008
c S100-120FT f 6/2008 →

12-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 12-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FREE-LIFT CYLINDER (FIGURE 12-7)

THREE STAGE FULL FREE-LIFT

12-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
S80FT 5/2008 AND UP

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4365 mm 4665 mm 4900 mm 5500 mm
1 2 3 4 (171.9 in.) (183.7 in.) (192.9 in.) (216.5 in.)
ITEM Mast B588 B588 B588 B588
Group Number 4365 4665 4900 5500
Cylinder
8544051 8544053 8544055 8501708
Group Number
Cylinder Assy 2104542 2104544 2104546 2104550
1 Tube Wldmt- 2073257 2073259 2073261 2073264
Cylinder
2 Cylinder Rod 2037833 2037835 2037836 2064925

S80FT UP TO 5/2008

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4365 mm 4665 mm 4900 mm 5500 mm
1 2 3 4 (171.9 in.) (183.7 in.) (192.9 in.) (216.5 in.)
ITEM Mast B588 B588 B588 B588
Group Number 4365 4665 4900 5500
Cylinder
8501701 8501703 8501704 8501708
Group Number
Cylinder Assy 2073395 2073397 2073398 2073402
1 Tube Wldmt- 2073257 2073259 2073260 2073264
Cylinder
2 Cylinder Rod 2073223 2073225 2073226 b2073230

S100-120FT 5/2008 AND UP

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4087 mm 4640 mm 5240 mm
1 2 3 4 (160.9 in.) (182.7 in.) (206.3 in.)
ITEM Mast B589 B589 B589
Group Number 4087 4640 5240
Cylinder
8518451 8518455 8518459
Group Number
Cylinder Assy 2104508 2104512 2104516
1 Tube Wldmt- 2073626 2073632 2073636
Cylinder
2 Cylinder Rod 2062074 2062077 2062081

©2011 HYSTER COMPANY See Service Manual 12-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
S100-120FT UP TO 5/2008

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4087 mm 4640 mm 5240 mm
1 2 3 4 (160.9 in.) (182.7 in.) (206.3 in.)
ITEM Mast B589 B589 B589
Group Number 4087 4640 5240
Cylinder
8527801 8527805 8527809
Group Number
Cylinder Assy 2073553 2073566 2073575
1 Tube Wldmt- 2073626 2073632 2073636
Cylinder
2 Cylinder Rod 2073681 2073685 2073689

KEY:
A: S80FT
B: S100-120FT
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
a. . . . . Cylinder Assy ........................................................................................... 1 1
1 a. . . . . Tube Wldmt-Cylinder ........................................................................... 1 1
2 a. . . . . Cylinder Rod ........................................................................................ 1 1
3 2036282 Gland ..................................................................................................... 1 ..
3 1541640 Gland ..................................................................................................... .. 1
4 1361302 Screw .................................................................................................... 1 1
5 257913 Check Valve ........................................................................................... 1 1
6 297531 Washer .................................................................................................. 1 1
7 187388 Snap Ring ............................................................................................. 1 1
8 1383070 Rod Wiper ............................................................................................. 1 1
9 637161 Rod Seal ................................................................................................ 1 1
9 2033395 Seal (Alternate Part) ............................................................................ 1 1
10 164632 Back-Up Ring ......................................................................................... 1 ..
10 615145 Back-Up Ring ....................................................................................... .. 1
11 15885 O-Ring ................................................................................................... .. 1
11 46629 O-Ring ................................................................................................... 1 ..
12 636950 Wear Ring .............................................................................................. 1 ..
12 1380982 Wear Ring ............................................................................................. .. 1
13 637162 Rod Seal ................................................................................................ 1 ..
13 364059 Rod Seal ............................................................................................... .. 1
14 638293 Back-Up Ring ......................................................................................... 1 ..
14 1381074 Back-Up Ring ....................................................................................... .. 1
15 190580 O-Ring ................................................................................................... .. 1
15 39348 O-Ring ................................................................................................... 1 ..
16 190887 Sealing Ring ......................................................................................... 1 1
17 1550195 Hyd Velocity Fuse (Free-Lift Cylinder) ....................................................... 1 ..
17 1550196 Hyd Velocity Fuse (Free-Lift Cylinder) ................................................... .. 1

12-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
KEY:
A: S80FT
B: S100-120FT
NOTE: This parts list contains multiple truck configurations, refer to the KEY to choose the correct QTY column
for your truck.
QTY
ITEM PART NO. DESCRIPTION A B
2036279 Kit-Seal (Includes Items 8-16) .................................................................... 1 ..
2065889 Kit-Seal (Includes Items 8-12, 14-16) ...................................................... .. 1

FOOTNOTES:
a Refer to Table c 5/2008 →
b → 5/2008

©2011 HYSTER COMPANY See Service Manual 12-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HEADER HOSE (FIGURE 12-8)

THREE STAGE FULL FREE-LIFT

12-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HEADER HOSE
THREE STAGE FULL FREE-LIFT
S80FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4365 mm 4665 mm 4900 mm 5500 mm
ITEM 1 2 3 4 (171.9 in.) (183.7 in.) (192.9 in.) (216.5 in.)
Mast B588 B588 B588 B588
Group Number 4365 4665 4900 5500
Mast Assy 2078199 2078201 2078202 2078206
1 Hose Assy 2078413 2078415 2078416 2078420
2 Hose Assy 2078413 2078415 2078416 2078420
31 Hose Assy 2077914 2077914 2077914 2077914
32 Hose Assy 2078050 2078052 2078054 2078058

S100-120FT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 4087 mm 4640 mm 5240 mm
ITEM 1 2 3 4 (160.9 in.) (182.7 in.) (206.3 in.)
Mast B589 B589 B589
Group Number 4087 4640 5240
Mast Assy 2078223 2078226 2078230
1 Hose Assy 2078437 2078440 2078444
2 Hose Assy 2078437 2078440 2078444
31 Hose Assy 2077914 2077914 2077914
32 Hose Assy 2078050 2078054 2078058

KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
b. . . . . Mast Assy ......................................................................................... 1 1 1
1 b. . . . . Hose Assy ........................................................................................ 2 2 2
2 b. . . . . Hose Assy ........................................................................................ .. 2 2
3 1581577 Capscrew ......................................................................................... 4 8 8
4 1581565 Nut .................................................................................................... 4 8 8
5 1387523 Bracket Wldmt ................................................................................. 1 2 2
6 1495279 Hose Sheave .................................................................................... 2 4 4
6 332057 Bushing ........................................................................................ 2 4 4
7 1581560 Washer ............................................................................................. 2 4 4
8 58902 Snap Ring ......................................................................................... 2 4 4
9 2035791 Hose Clamp ...................................................................................... 3 6 6
10 1581741 Capscrew ......................................................................................... 2 4 4
11 1360507 Clamp ............................................................................................... 2 4 6
12 1465489 Hose Clamp ...................................................................................... 2 4 4
©2011 HYSTER COMPANY See Service Manual 12-29
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HEADER HOSE
THREE STAGE FULL FREE-LIFT
KEY:
A: Three Function
B: Four Function
C: Five Function
QTY
ITEM PART NO. DESCRIPTION A B C
13 1387327 Bracket ............................................................................................. 1 1 1
14 1581556 Washer ............................................................................................. 2 4 4
15 1581562 Lockwasher ...................................................................................... 2 4 4
16 1581579 Capscrew ......................................................................................... 2 4 4
17 1541242 Bracket Wldmt (RH) ......................................................................... 1 1 1
18 302472 Roll Pin ............................................................................................. 2 2 2
19 1528580 Fitting (Includes Nut) ...................................................................... 1 2 2
20 1550425 Fitting ............................................................................................... 1 2 2
21 1581587 Capscrew ......................................................................................... 2 4 4
22 1581563 Lockwasher ...................................................................................... 2 4 4
23 1389828 Bracket ............................................................................................. 1 1 1
24 1502809 Hose Clamp ...................................................................................... 2 2 2
25 1399243 Clamp ............................................................................................... 1 1 1
26 1581586 Capscrew ......................................................................................... 1 1 1
27 1581567 Nut .................................................................................................... 1 1 1
28 1389854 Bracket ............................................................................................. .. 1 1
29 320157 Washer ............................................................................................. .. 2 2
30 1541243 Bracket Wldmt (LH) ......................................................................... .. 1 1
31 b. . . . . Hose Assy ........................................................................................ .. .. 1
32 b. . . . . Hose Assy ........................................................................................ .. .. 2
33 358286 Strain Relief ....................................................................................... .. .. 1
34 358287 Bracket .............................................................................................. .. .. 1
35 cd 1703560 Capscrew .......................................................................................... .. .. 2
35 ef 1597442 Capscrew .......................................................................................... .. .. 2
35 ef 1597442 Capscrew (Without Side-Shift) .......................................................... .. .. 3
36 cd 1581563 Lockwasher ...................................................................................... .. .. 2
36 ef 1581563 Lockwasher (Without Side-Shift) ................................................... .. .. 4
37 358289 Hose Reel .......................................................................................... .. .. 1
37 672563 Kit-Seal .......................................................................................... .. .. 1
38 1473887 Fitting ............................................................................................... .. .. 4
38 265731 O-Ring ........................................................................................... .. .. 1
38 16484 O-Ring .......................................................................................... .. .. 1
39 1618437 Plate .................................................................................................. .. .. 1
40 1581594 Capscrew .......................................................................................... .. .. 2
41 1581559 Washer ............................................................................................. .. .. 2
42 cd 1597853 Plate (Without side-shift) ................................................................... .. .. 1
42 ef 1705595 Bracket (Without side-shift) ............................................................... .. .. 1
42 ef 136692 Nut (Without side-shift) ...................................................................... .. .. 1
42 1599322 Plate (With side-shift) ........................................................................ .. .. 1
43 1502809 Hose Clamp ...................................................................................... .. .. 2
44 1556897 Fitting ................................................................................................. .. .. 2
45 1581590 Capscrew ......................................................................................... 2 .. ..
a 1566564 Cap .................................................................................................... 1 1 1

12-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FOOTNOTES:
a Not Illustrated d → S/N B589V02912G
b Refer to Table e S/N B588V02461G →
c → S/N B588V02460G f S/N B589V02913G →

©2011 HYSTER COMPANY See Service Manual 12-31

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

CARRIAGE (FIGURE 12-9)

THREE STAGE FULL FREE-LIFT

12-32 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

CARRIAGE
THREE STAGE FULL FREE-LIFT
KEY:
A: S80FT
B: S100-120FT
C: S100 (Atachment)
QTY
ITEM PART NO. DESCRIPTION A B C
1401665 Carriage (42 in.) ................................................................................ 1 .. ..
2108029 Carriage (42 in.) (Alternate Part) ....................................................... 1 .. ..
1401666 Carriage (48 in.) ................................................................................ 1 .. ..
2108030 Carriage (48 in.) (Alternate Part) ....................................................... 1 .. ..
1401667 Carriage (42 in.) ................................................................................ .. 1 ..
2108037 Carriage (42 in.) (Alternate Part) .................................................... .. 1 ..
1401668 Carriage (48 in.) ................................................................................ .. 1 ..
2108038 Carriage (48 in) (Alternate Part) ........................................................ .. 1 ..
1401669 Carriage (42 in.) ................................................................................ .. .. 1
2108032 Carriage (42 in.) (Alternate Part) ....................................................... .. .. 1
1401688 Carriage (48 in.) ................................................................................ .. .. 1
2108033 Carriage (48 in.) (Alternate Part) ....................................................... .. .. 1
1 1401635 Carriage Wldmt (42 in.) ................................................................. 1 .. ..
1 1694398 Carriage Wldmt (42 in.) (Alternate Part) ........................................ 1 .. ..
1 1401636 Carriage Wldmt (48 in.) ................................................................. 1 .. ..
1 1694399 Carriage Wldmt (48 in.) (Alternate Part) ........................................ 1 .. ..
1 1401637 Carriage Wldmt (42 in.) ................................................................. .. 1 ..
1 1692203 Carriage Wldmt (42 in.) (Alternate Part) .................................... .. 1 ..
1 1401638 Carriage Wldmt (48 in.) ................................................................. .. 1 ..
1 1692687 Carriage Wldmt (48 in.) (Alternate Part) ........................................ .. 1 ..
1 1401639 Carriage Wldmt (42 in.) ................................................................. .. .. 1
1 1694595 Carriage Wldmt (42 in.) (Alternate Part) ........................................ .. .. 1
1 1401648 Carriage Wldmt (48 in.) ................................................................. .. .. 1
1 1694596 Carriage Wldmt (48 in.) (Alternate Part) ........................................ .. .. 1
2 1500744 Stubshaft ................................................................................. 6 6 6
3 1465177 Bracket ......................................................................................... .. .. 2
4 1387993 Side Roller ..................................................................................... .. .. 2
4 1670064 Cam Follower (Alternate Part) .................................................... .. .. 2
5 1465028 Pin ................................................................................................. .. .. 2
5 1670065 Pin (Alternate Part) ...................................................................... .. .. 2
6 292683 Lockwasher ................................................................................. .. .. 4
7 292528 Capscrew ..................................................................................... .. .. 4
8 319323 Bracket Wldmt (LH) ..................................................................... 1 1 1
9 319322 Bracket Wldmt (RH) .................................................................... 1 1 1
10 1624590 Chain Anchor ............................................................................... 2 2 2
11 339932 Pin ................................................................................................. 2 2 2
12 15222 Cotter Pin ..................................................................................... 2 2 2
13 1465072 Snap Ring .................................................................................... 6 6 6
14 1399224 Spacer .......................................................................................... 2 2 2
15 126765 Shim ............................................................................................. 24 24 24
16 1511883 Load Roller ("B") (104.44/104.18) ............................................... 6 6 6
17 317292 Spacer .......................................................................................... 4 4 4
18 18518 Capscrew ..................................................................................... 4 4 4
19 15155 Lockwasher ................................................................................. 4 4 4

©2011 HYSTER COMPANY See Service Manual 12-33

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

CARRIAGE
THREE STAGE FULL FREE-LIFT
KEY:
A: S80FT
B: S100-120FT
C: S100 (Atachment)
QTY
ITEM PART NO. DESCRIPTION A B C
20 1624589 Pin ................................................................................................. 2 2 2
21 131358 Snap Ring .................................................................................... 2 2 2
22 66333 Roll Pin ......................................................................................... .. .. 2
23 16001 Grease Fitting .............................................................................. .. .. 2
24 192425 Shim (0.062 in.) ............................................................................ .. .. AR
25 192424 Shim (0.030 in.) ............................................................................ .. .. AR

12-34 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 12-35

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 12-10)

THREE STAGE FULL FREE-LIFT (→ S/N B588V02594G) (→ S/N B589V03131G)

12-36 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

THREE STAGE FULL FREE-LIFT (→ S/N B588V02594G) (→ S/N B589V03131G)
KEY:
A: B588 Three Function
B: B589 Three Function
C: B588 Four Function
D: B589 Four Function
QTY
ITEM PART NO. DESCRIPTION A B C D
1 1529016 Fitting ........................................................................................ 2 2 2 2
1 265731 O-Ring .................................................................................. 1 1 1 1
2 d 816591 Fitting (Includes Nut) ................................................................. 2 2 2 2
3 1643681 Bracket ...................................................................................... 1 1 1 1
3 1705597 Bracket (LH) (Alternate Part) .................................................... 1 1 1 1
3 1597442 Capscrew (Alternate Part) ........................................................ 2 2 2 2
3 c 1644483 Formed Bracket (Alternate Part) ............................................... .. .. 1 1
3 1581563 Lockwasher (Alternate Part) ..................................................... 2 2 2 2
4 2088711 Tube Assy ................................................................................. .. .. 1 ..
4 2089900 Tube Assy ................................................................................. .. .. .. 1
4 c 2088905 Tube Assy ................................................................................. .. .. 1 ..
4 c 2089904 Tube Assy ................................................................................. .. .. .. 1
4 b 2088909 Tube Assy ................................................................................. .. .. .. 1
5 2088712 Tube Assy ................................................................................. .. .. 1 ..
5 2089901 Tube Assy ................................................................................. .. .. .. 1
5 c 2088906 Tube Assy ................................................................................. .. .. 1 ..
5 c 2089905 Tube Assy ................................................................................. .. .. .. 1
5 b 2088910 Tube Assy ................................................................................. .. .. .. 1
6 2088710 Tube Assy ................................................................................. 1 .. .. ..
6 b 2088908 Tube Assy ................................................................................. .. 1 .. ..
7 2088709 Tube Assy ................................................................................. 1 .. .. ..
7 b 2088907 Tube Assy ................................................................................. .. 1 .. ..
8 bef 1706021 Bracket (Right Hand) ................................................................ 1 1 1 1
8 bgh 1705595 Bracket (Right Hand) ................................................................ 1 1 1 1
8 gh 1597442 Capscrew .................................................................................. 2 2 2 2
8 gh 1581563 Lockwasher ............................................................................... 2 2 2 2
9 1622610 Fitting ........................................................................................ 2 2 2 2
9 16484 O-Ring .................................................................................. 1 1 1 1
9 265731 O-Ring .................................................................................. 2 2 2 2
10 1377954 Fitting ........................................................................................ 2 2 2 2
11 1377953 Quick Disconnect Fitting ........................................................... 2 2 2 2
12 16541 Fitting ........................................................................................ 1 1 1 1
13 16484 O-Ring .................................................................................. 1 1 1 1
14 1473887 Fitting ........................................................................................ 2 2 2 2
14 265731 O-Ring .................................................................................. 1 1 1 1
14 16484 O-Ring .................................................................................. 1 1 1 1
15 2087565 Drain Valve ............................................................................... 1 1 1 1
a 181298 Dust Cap ................................................................................... 1 1 1 1
a 181266 Dust Cap ................................................................................... 1 1 1 1

©2011 HYSTER COMPANY See Service Manual 12-37

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a Not Illustrated
b Used With Attachment Carriage
c Used With Integral Side-Shift Carriage
d Used Without Quick Disconnect Fittings
e → S/N B588V02460G
f → S/N B589V02912G
g S/N B588V02461G →
h S/N B589V02913G →

12-38 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NOTES

©2011 HYSTER COMPANY See Service Manual 12-39

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 12-11)

THREE STAGE FULL FREE-LIFT — WITHOUT QUICK DISCONNECT FITTINGS (S/N B588V02595G →)
(S/N B589V03132G →)

12-40 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

THREE STAGE FULL FREE-LIFT – WITHOUT QUICK DISCONNECT FITTINGS (S/N B588V02595G →)
(S/N B589V03132G →)
KEY:
A: B588, 3 Function
B: B588, Four Function
C: B589, Three Function
D: B589, Four Function
QTY
ITEM PART NO. DESCRIPTION A B C D
1 1705595 Bracket (RH) ............................................................................. 1 1 1 1
2 816591 Fitting (Includes Nut) ................................................................. 2 4 2 4
3 1706021 Bracket (LH) .............................................................................. 1 1 1 1
3 b 1644483 Formed Bracket (LH) ................................................................ .. 1 .. 1
4 1581563 Lockwasher ............................................................................... 2 4 2 4
5 1597443 Bolt ............................................................................................ 2 4 2 4
6 a 2088908 Tube Assy ................................................................................. .. .. 1 1
6 2089899 Tube Assy ................................................................................. .. .. 1 1
6 2088710 Tube Assy ................................................................................. 1 1 .. ..
7 2088711 Tube Assy ................................................................................. .. 1 .. ..
7 b 2088905 Tube Assy ................................................................................. .. 1 .. ..
7 2089900 Tube Assy ................................................................................. .. .. .. 1
7 b 2089904 Tube Assy ................................................................................. .. .. .. 1
7 a 2088910 Tube Assy ................................................................................. .. .. .. 1
8 2088712 Tube Assy ................................................................................. .. 1 .. ..
8 b 2088906 Tube Assy ................................................................................. .. 1 .. ..
8 2089901 Tube Assy ................................................................................. .. .. .. 1
8 b 2089905 Tube Assy ................................................................................. .. .. .. 1
8 a 2088909 Tube Assy ................................................................................. .. .. .. 1
9 2088709 Tube Assy ................................................................................. 1 1 .. ..
9 2089898 Tube Assy ................................................................................. .. .. 1 1
9 a 2088907 Tube Assy ................................................................................. .. .. 1 1

FOOTNOTES:
a Used with Attachment Carriage b Used with ISS Carriage

©2011 HYSTER COMPANY See Service Manual 12-41

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 12-12)

THREE STAGE FULL FREE-LIFT — MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B588V02595G →) (S/N B589V03132G →)

12-42 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

THREE STAGE FULL FREE-LIFT – MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B588V02595G →) (S/N B589V03132G →)
KEY:
A: B588, Three Function
B: B588, Four Function
C: B589, Three Function
D: B589, Four Function
QTY
ITEM PART NO. DESCRIPTION A B C D
1 1705595 Bracket (RH) ............................................................................. 1 1 1 1
2 1473887 Fitting ........................................................................................ 2 4 2 4
3 1377953 Quick Disconnect Fitting ........................................................... 2 4 2 4
4 1377954 Fitting (Quick Disconnect) ......................................................... 2 4 2 4
5 1708368 Dust Cover ................................................................................ 2 4 2 4
6 1708365 Bulkhead (Fitting) ...................................................................... 2 4 2 4
7 1581563 Lockwasher ............................................................................... 2 4 2 4
8 1597443 Bolt ............................................................................................ 2 4 2 4
9 b 1706021 Bracket (LH) .............................................................................. .. 1 .. 1
9 1644483 Formed Bracket (LH) ................................................................ .. 1 .. 1
10 a 2088908 Tube Assy ................................................................................. .. .. 1 1
10 2089899 Tube Assy ................................................................................. .. .. 1 1
10 2088710 Tube Assy ................................................................................. 1 1 .. ..
11 2088711 Tube Assy ................................................................................. .. 1 .. ..
11 b 2088905 Tube Assy ................................................................................. .. 1 .. ..
11 2089900 Tube Assy ................................................................................. .. .. .. 1
11 b 2089904 Tube Assy ................................................................................. .. .. .. 1
11 a 2088910 Tube Assy ................................................................................. .. .. .. 1
12 2088712 Tube Assy ................................................................................. .. 1 .. ..
12 b 2088906 Tube Assy ................................................................................. .. 1 .. ..
12 2089901 Tube Assy ................................................................................. .. .. .. 1
12 b 2089905 Tube Assy ................................................................................. .. .. .. 1
12 a 2088909 Tube Assy ................................................................................. .. .. .. 1
13 2088709 Tube Assy ................................................................................. 1 1 .. ..
13 2089898 Tube Assy ................................................................................. .. .. 1 1
13 a 2088907 Tube Assy ................................................................................. .. .. 1 1

FOOTNOTES:
a Used with Attachment Carriage b Used with ISS Carriage

©2011 HYSTER COMPANY See Service Manual 12-43

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSIONS (FIGURE 12-13)

THREE STAGE FULL FREE-LIFT — E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B588V02595G →) (S/N B589V03132G →)

12-44 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

AUXILIARY TUBE EXTENSIONS

THREE STAGE FULL FREE-LIFT – E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS
(S/N B588V02595G →) (S/N B589V03132G →)
KEY:
A: B588, Three Function
B: B588, Four Function
C: B589, Three Function
D: B589, Four Function
QTY
ITEM PART NO. DESCRIPTION A B C D
1 1487095 Fitting ........................................................................................ 2 4 2 4
2 4604566 Hose Assy ................................................................................. 1 2 1 2
2 b 4604567 Hose Assy ................................................................................. .. 1 .. 1
3 4604565 Hose Assy ................................................................................. 1 2 1 2
3 b 4604566 Hose Assy ................................................................................. .. 1 .. 1
4 2111754 Valve (Single Aux) .................................................................... 1 .. 1 ..
4 2111755 Valve (Dual Aux) ....................................................................... .. 1 .. 1
5 110178 Fitting ........................................................................................ 1 1 1 1
5 16483 O-Ring .................................................................................. 1 1 1 1
6 1527979 Hose Clamp .............................................................................. 4 4 4 4
7 2046871 Fitting ........................................................................................ 1 1 1 1
8 292505 Capscrew .................................................................................. .. 2 .. 2
9 1473887 Fitting ........................................................................................ 2 4 2 4
10 1377954 Fitting (Quick Disconnect) ......................................................... 2 4 2 4
11 1377953 Quick Disconnect Fitting ........................................................... 2 4 2 4
12 1708368 Dust Cover ................................................................................ 2 4 2 4
13 1708365 Bulkhead ................................................................................... 2 4 2 4
14 1705595 Bracket (RH) ............................................................................. 1 1 1 1
15 1581563 Lockwasher ............................................................................... 2 4 2 4
16 1597443 Bolt ............................................................................................ 2 4 2 4
17 1614069 Hose ......................................................................................... 1 1 1 1
18 2088710 Tube Assy ................................................................................. 1 1 .. ..
18 2089899 Tube Assy ................................................................................. .. .. 1 1
18 a 2088908 Tube Assy ................................................................................. .. .. 1 1
19 2088709 Tube Assy ................................................................................. 1 1 .. ..
19 2089898 Tube Assy ................................................................................. .. .. 1 1
19 a 2088907 Tube Assy ................................................................................. .. .. 1 1
20 1708373 Bracket ...................................................................................... 1 1 1 1
21 1527885 Capscrew .................................................................................. 2 2 2 2
22 2088712 Tube Assy ................................................................................. .. 1 .. ..
22 b 2088906 Tube Assy ................................................................................. .. 1 .. ..
22 2089901 Tube Assy ................................................................................. .. .. .. 1
22 b 2089905 Tube Assy ................................................................................. .. .. .. 1
22 a 2088909 Tube Assy ................................................................................. .. .. .. 1
23 2088711 Tube Assy ................................................................................. .. 1 .. ..
23 b 2088905 Tube Assy ................................................................................. .. 1 .. ..
23 2089900 Tube Assy ................................................................................. .. .. .. 1
23 b 2089904 Tube Assy ................................................................................. .. .. .. 1
23 a 2088909 Tube Assy ................................................................................. .. .. .. 1
24 1706021 Bracket (LH) .............................................................................. .. 1 .. 1
24 b 1644483 Formed Bracket (LH) ................................................................ .. 1 .. 1
25 1486737 Fitting ........................................................................................ 4 4 4 4

©2011 HYSTER COMPANY See Service Manual 12-45

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

FOOTNOTES:
a Used with Attachment Carriage b Used with ISS Carriage

12-46 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

13 OPTIONS
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 13
OPTIONS

DESCRIPTION PAGE

ACCUMULATOR ............................................................................................................................................. 13-18

BACK-UP ALARM
COUNTERWEIGHT MOUNTED (→ 5/2009) ............................................................................................. 13-10
OVERHEAD GUARD MOUNTED (5/2009 →) ........................................................................................... 13-12
BOLT-ON FENDERS ...................................................................................................................................... 13-2
FIRE EXTINGUISHER .................................................................................................................................... 13-9
GM LPG REGULATOR DRAIN KIT ................................................................................................................ 13-16
INTEGRAL SIDE-SHIFT
THREE STAGE FULL FREE-LIFT - S80FT ................................................................................................ 13-34
TWO AND THREE STAGE FULL FREE-LIFT - S100-120FT ..................................................................... 13-40
TWO STAGE FULL FREE-LIFT - S80FT .................................................................................................... 13-28
TWO STAGE LIMITED FREE-LIFT - S80-120FT ....................................................................................... 13-20
INTEGRAL SIDE-SHIFT CARRIAGE
THREE STAGE FULL FREE-LIFT - 1067 MM (42 IN.) CLASS III .............................................................. 13-36
THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III .............................................................. 13-38
THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV .............................................................. 13-44
TWO STAGE FULL FREE-LIFT - 1067 MM (42 IN.) CLASS III .................................................................. 13-30
TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III .................................................................. 13-32
TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV ................................................................. 13-42
TWO STAGE LIMITED FREE-LIFT - 1067 MM (42 IN.) CLASS III ............................................................ 13-22
TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS III ............................................................ 13-24
TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS IV ............................................................ 13-26
MIRROR .......................................................................................................................................................... 13-7
REAR MOUNTED ....................................................................................................................................... 13-8
PRESSURE REGULATOR ............................................................................................................................. 13-14
STROBE LIGHT
→ S/N G004V02783E EXC. 02746, 02754-02758 ..................................................................................... 13-4
LED (S/N G004V02784E → INC. 02746, 02754-02758) ........................................................................... 13-6

©2011 HYSTER COMPANY See Service Manual 13-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BOLT-ON FENDERS (FIGURE 13-1)

13-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BOLT-ON FENDERS
ITEM PART NO. DESCRIPTION QTY
1 1692342 Fender (Bolt-On) (LH) ......................................................................................... 1
1 1692343 Fender (Bolt-On) (RH) ........................................................................................ 1
2 1565195 Capscrew ............................................................................................................ 6
3 1460477 Nut ...................................................................................................................... 6

©2011 HYSTER COMPANY See Service Manual 13-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STROBE LIGHT (FIGURE 13-2)

(→ S/N G004V02783E EXC. 02746, 02754-02758)

13-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

STROBE LIGHT
(→ S/N G004V02783E EXC. 02746, 02754-02758)

ITEM PART NO. DESCRIPTION QTY

1 1581670 Strobe Light ........................................................................................................ 1
1 1382130 Strobe Light .................................................................................................... 1
2 1673704 Lamp .......................................................................................................... 1
3 1673755 Lens ........................................................................................................... 1
4 1463138 Terminal ......................................................................................................... 2
4 1561755 Connector ....................................................................................................... 1
4 1561559 Connector ....................................................................................................... 2
5 1565076 Bracket Wldmt .................................................................................................... 1
6 1586428 Nut ...................................................................................................................... 2
7 2073760 Wire Harness (Lights) ......................................................................................... 1
8 1539584 Grommet ............................................................................................................. 1
9 1586759 Capscrew ............................................................................................................ 2
10 1586495 Capscrew ............................................................................................................ 2
11 1531001 Insert ................................................................................................................... 2
12 1302024 Guard .................................................................................................................. 1

©2011 HYSTER COMPANY See Service Manual 13-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

STROBE LIGHT (FIGURE 13-3)

LED (S/N G004V02784E → INC. 02746, 02754-02758)

ITEM PART NO. DESCRIPTION QTY

1654013 Strobe Light Assembly ..................................................................................... 1
1 1652290 Strobe Light (LED) ........................................................................................ 1
2 1463138 Terminal ........................................................................................................ 1
2 1561559 Connector ..................................................................................................... 1
2 1561755 Connector ..................................................................................................... 1

13-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

MIRROR (FIGURE 13-4)

ITEM PART NO. DESCRIPTION QTY

1 4009488 Mirror .................................................................................................................. 2
2 1656215 Bracket (RH) ....................................................................................................... 1
2 1656216 Bracket (LH) ........................................................................................................ 1
3 1583611 Capscrew ............................................................................................................ 4
4 1502543 Nut (Flange) ........................................................................................................ 4

©2011 HYSTER COMPANY See Service Manual 13-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

MIRROR (FIGURE 13-5)

REAR MOUNTED

ITEM PART NO. DESCRIPTION QTY

1 4009488 Mirror .................................................................................................................. 1
2 1502543 Nut (Flange) ........................................................................................................ 1
3 1619518 Bracket ................................................................................................................ 1
3 1675655 Bracket (With 80 Box Car Special) ..................................................................... 1
4 1301286 Mirror .................................................................................................................. 1
a 1580788 Plate (Warning) ................................................................................................... 1

FOOTNOTES:
a Not Illustrated

13-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

FIRE EXTINGUISHER (FIGURE 13-6)

ITEM PART NO. DESCRIPTION QTY

1 146540 Fire Extinguisher ................................................................................................. 1
1 1561749 Bracket ........................................................................................................... 1
2 1641394 Bracket ................................................................................................................ 1
3 296507 Screw .................................................................................................................. 2
4 292679 Washer ............................................................................................................... 2
5 320155 Washer ............................................................................................................... 2
6 1583611 Capscrew ............................................................................................................ 1
7 1502543 Nut (Flange) ........................................................................................................ 1

©2011 HYSTER COMPANY See Service Manual 13-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BACK-UP ALARM (FIGURE 13-7)

COUNTERWEIGHT MOUNTED (→ 5/2009)

13-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BACK-UP ALARM
COUNTERWEIGHT MOUNTED (→ 5/2009)

ITEM PART NO. DESCRIPTION QTY

1 1582464 Fastener ............................................................................................................. 1
2 1500912 Clip ..................................................................................................................... 1
3 1350215 Nut ...................................................................................................................... 2
4 1527877 Capscrew ........................................................................................................... 2
5 2064929 Back-Up Alarm (82-102 dbA) ........................................................................... 1

©2011 HYSTER COMPANY See Service Manual 13-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

BACK-UP ALARM (FIGURE 13-8)

OVERHEAD GUARD MOUNTED (5/2009 →)

13-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

BACK-UP ALARM
OVERHEAD GUARD MOUNTED (5/2009 →)

ITEM PART NO. DESCRIPTION QTY

1 2071261 Capscrew ........................................................................................................... 2
2 1463910 Capscrew ........................................................................................................... 2
3 2064929 Back-Up Alarm (82-102 dbA) ........................................................................... 1
4 1705479 Bracket ............................................................................................................... 1
5 292653 Nut ...................................................................................................................... 2
6 4600272 Wire Harness ..................................................................................................... 1
7 1582464 Fastener ............................................................................................................. 1
8 1500912 Clip ..................................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 13-13

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

PRESSURE REGULATOR (FIGURE 13-9)

13-14 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

PRESSURE REGULATOR
ITEM PART NO. DESCRIPTION QTY
1 1606909 Capscrew ............................................................................................................ 2
2 1581739 Nut ...................................................................................................................... 2
3 c 1606802 Bracket ................................................................................................................ 1
3 d 1683472 Bracket ................................................................................................................ 1
4 d 2104109 Pressure Regulator (Relief) ................................................................................ 1
4 c 4000712 Relief Valve .................................................................................................... 3
4 323488 Kit-Seal ....................................................................................................... 1
5 1581898 Washer ............................................................................................................... 2
6 c 1606910 Capscrew ............................................................................................................ 2
6 d 1683502 Capscrew ............................................................................................................ 2
7 c 1532404 Knob ................................................................................................................... 1
8 c 19926 Roll Pin ............................................................................................................... 1
9 2079436 Hose Assy ........................................................................................................... 1
10 379405 Clamp ................................................................................................................. 4
11 b 2046871 Fitting .................................................................................................................. 1
12 b 78561 Hose Assy ........................................................................................................... 1
12 a 155671 Hose ................................................................................................................... 1
12 1399116 Hose Assy (Alternate Part) ................................................................................. 1
13 b 182005 Hose ................................................................................................................... 1
14 1487095 Fitting .................................................................................................................. 1
14 265731 O-Ring ............................................................................................................ 2
15 1486747 Fitting .................................................................................................................. 1
15 265731 O-Ring ............................................................................................................ 1
15 16486 O-Ring ............................................................................................................ 1
16 222456 Fitting .................................................................................................................. 1
16 16486 O-Ring ............................................................................................................ 1
17 222510 Fitting .................................................................................................................. 1
17 16484 O-Ring ............................................................................................................ 1
18 1487086 Fitting .................................................................................................................. 1
18 265731 O-Ring ............................................................................................................ 3
19 1606823 Fitting .................................................................................................................. 1
20 2060480 Oil Pressure Gauge ............................................................................................ 1
21 a 110178 Fitting .................................................................................................................. 1
21 a 16483 O-Ring ............................................................................................................ 1
a 1502059 Clamp (Not Illustrated) ........................................................................................ 1
a 1502066 Clamp (Not Illustrated) ........................................................................................ 1

FOOTNOTES:
a Used with Two Stage Full Free-Lift Masts c → 9/2008
b Used with Two Stage Limited Fee-Lift and Three d 9/2008 →
Stage Full Free-Lift Masts

©2011 HYSTER COMPANY See Service Manual 13-15

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

GM LPG REGULATOR DRAIN KIT (FIGURE 13-10)

13-16 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

GM LPG REGULATOR DRAIN KIT

ITEM PART NO. DESCRIPTION QTY
1664940 Kit-Service (GM LPG regulator Drain GM2.4L and 4.32) ................................... 1
1 1652140 Fitting .................................................................................................................. 1
2 16481 O-Ring ................................................................................................................ 1
3 69392 Fitting .................................................................................................................. 1
4 28584 Fitting .................................................................................................................. 1
5 1488404 Fitting .................................................................................................................. 1
6 1529014 Fitting .................................................................................................................. 1
6 1527813 O-Ring ............................................................................................................ 1
7 a 273338 Thread Sealant ................................................................................................... 1

FOOTNOTES:
a Not Shown

©2011 HYSTER COMPANY See Service Manual 13-17

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

ACCUMULATOR (FIGURE 13-11)

13-18 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ACCUMULATOR
ITEM PART NO. DESCRIPTION QTY
1 1629185 Accumulator ........................................................................................................ 1
1 1465897 Accumulator (Alternate Part) .............................................................................. 1
2 1609864 Spacer ................................................................................................................ 2
3 1611564 Clamp ................................................................................................................. 2
4 2091868 Hose Assy ........................................................................................................... 1
5 1487096 Fitting .................................................................................................................. 1
5 252729 O-Ring ............................................................................................................ 3

©2011 HYSTER COMPANY See Service Manual 13-19

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT (FIGURE 13-12)

TWO STAGE LIMITED FREE-LIFT — S80-120FT

13-20 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT
TWO STAGE LIMITED FREE-LIFT – S80-120FT
KEY:
A: S80FT
B: S100-120FT
QTY
ITEM PART NO. DESCRIPTION A B
1401675 Side-Shift Carriage (42 in.) ......................................................................... 1 ..
1401676 Side-Shift Carriage (48 in.) ......................................................................... 1 ..
1401678 Side-Shift Carriage (48 in.) ......................................................................... .. 1
1 1401695 Carriage (42 in.) (FFigure 13-13).......................................................... 1 ..
1 1401696 Carriage (48 in.) (FFigure 13-14).......................................................... 1 ..
1 1401698 Carriage (48 in.) (FFigure 13-15).......................................................... .. 1
2 221717 Nut ......................................................................................................... 4 4
3 15222 Cotter Pin ............................................................................................... 2 2
4 327591 Pin .......................................................................................................... 2 ..
4 339932 Pin .......................................................................................................... .. 2
5 1387285 Chain Anchor ......................................................................................... 2 ..
5 1387286 Chain Anchor ......................................................................................... .. 2
6 1465177 Bracket ................................................................................................... 2 2
7 292683 Lockwasher ............................................................................................ 4 4
8 292528 Capscrew ............................................................................................... 4 4
9 66333 Roll Pin .................................................................................................. 2 2
10 16001 Grease Fitting ........................................................................................ 2 2
11 1465028 Pin .......................................................................................................... 2 2
11 1670065 Pin (Alternate Part) ................................................................................ 2 2
12 1387993 Side Roller ............................................................................................. 2 2
12 1670064 Cam Follower (Alternate Part) ............................................................... 2 2
13 192425 Shim (0.062 in.) ..................................................................................... 6 6
14 192424 Shim (0.030 in.) ..................................................................................... 8 8
15 1465072 Snap Ring .............................................................................................. 6 6
16 126765 Shim ....................................................................................................... 24 24
17 1399224 Spacer ................................................................................................... 2 2
18 1511883 Load Roller ("B") (104.44/104.18) .......................................................... 6 ..
19 1473897 Fitting ..................................................................................................... 2 2
19 265731 O-Ring ............................................................................................... 1 1
19 16484 O-Ring ............................................................................................... 1 1
20 2078114 Hose Assy .............................................................................................. 1 1
21 2078113 Hose Assy .............................................................................................. 1 1
22 1473887 Fitting ..................................................................................................... 1 1
22 16484 O-Ring ............................................................................................... 1 1
22 265731 O-Ring ............................................................................................... 1 1

©2011 HYSTER COMPANY See Service Manual 13-21

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT CARRIAGE (FIGURE 13-13)

TWO STAGE LIMITED FREE-LIFT — 1067 MM (42 IN.) CLASS III

13-22 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT CARRIAGE

TWO STAGE LIMITED FREE-LIFT – 1067 MM (42 IN.) CLASS III

ITEM PART NO. DESCRIPTION QTY

1401695 Carriage (42 in.) .................................................................................................. 1
1 1518331 Frame ............................................................................................................. 1
2 1467147 Wear Strip (Right Upper) ................................................................................ 1
3 1467148 Wear Strip (Left Upper) .................................................................................. 1
4 16041 Grease Fitting ................................................................................................. 8
5 1622935 Seal ................................................................................................................ 2
6 1467151 Bushing .......................................................................................................... 2
7 1467150 Rod Wiper ...................................................................................................... 2
8 1467632 Snap Ring ....................................................................................................... 2
9 1467153 Rod ................................................................................................................. 2
10 39365 O-Ring ............................................................................................................ 2
11 1467145 Wear Strip (Right Lower) ................................................................................ 1
12 1467146 Wear Strip (Left Lower) .................................................................................. 1
13 1532644 Apron .............................................................................................................. 1
14 1467154 Hook ............................................................................................................... 2
15 1467633 Screw ............................................................................................................. 6
2083999 Kit-Seal (Class III) (Includes Items 5, 7, 10) ....................................................... 1

©2011 HYSTER COMPANY See Service Manual 13-23

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT CARRIAGE (FIGURE 13-14)

TWO STAGE LIMITED FREE-LIFT — 1219 MM (48 IN.) CLASS III

13-24 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT CARRIAGE

TWO STAGE LIMITED FREE-LIFT – 1219 MM (48 IN.) CLASS III

ITEM PART NO. DESCRIPTION QTY

1401696 Carriage (48 in.) .................................................................................................. 1
1 1518333 Frame ............................................................................................................. 1
2 1467147 Wear Strip (Right Upper) ................................................................................ 1
3 1467148 Wear Strip (Left Upper) .................................................................................. 1
4 16041 Grease Fitting ................................................................................................. 8
5 1622935 Seal ................................................................................................................ 2
6 1467151 Bushing .......................................................................................................... 2
7 1467150 Rod Wiper ...................................................................................................... 2
8 1467632 Snap Ring ....................................................................................................... 2
9 1467153 Rod ................................................................................................................. 2
10 39365 O-Ring ............................................................................................................ 2
11 1467145 Wear Strip (Right Lower) ................................................................................ 1
12 1467146 Wear Strip (Left Lower) .................................................................................. 1
13 1532645 Apron .............................................................................................................. 1
14 1467154 Hook ............................................................................................................... 2
15 1467633 Screw ............................................................................................................. 6
2083999 Kit-Seal (Class III) (Includes Items 5, 7, 10) ....................................................... 1

©2011 HYSTER COMPANY See Service Manual 13-25

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT CARRIAGE (FIGURE 13-15)

TWO STAGE LIMITED FREE-LIFT — 1219 MM (48 IN.) CLASS IV

13-26 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT CARRIAGE

TWO STAGE LIMITED FREE-LIFT – 1219 MM (48 IN.) CLASS IV

ITEM PART NO. DESCRIPTION QTY

1401698 Carriage (48 in.) .................................................................................................. 1
1 1518342 Frame ............................................................................................................. 1
2 1467200 Wear Strip ...................................................................................................... 2
3 1467147 Wear Strip (Right Upper) ................................................................................ 1
4 1467145 Wear Strip (Right Lower) ................................................................................ 1
5 1467148 Wear Strip (Left Upper) .................................................................................. 1
6 16041 Grease Fitting ................................................................................................. 8
7 1622936 Seal ................................................................................................................ 2
8 1467204 Bushing .......................................................................................................... 2
9 1467203 Rod Wiper ...................................................................................................... 2
10 39366 O-Ring ............................................................................................................ 2
11 1467205 Rod ................................................................................................................. 2
12 1467201 Wear Strip ...................................................................................................... 2
13 1467146 Wear Strip (Left Lower) .................................................................................. 1
14 1532637 Apron .............................................................................................................. 1
15 1467634 Snap Ring ....................................................................................................... 2
16 1467206 Hook ............................................................................................................... 2
17 1467633 Screw ............................................................................................................. 8
2083998 Kit-Seal (Class IV) (Includes Items 7, 9-10) ........................................................ 1

©2011 HYSTER COMPANY See Service Manual 13-27

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT (FIGURE 13-16)

TWO STAGE FULL FREE-LIFT — S80FT

13-28 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT
TWO STAGE FULL FREE-LIFT – S80FT

ITEM PART NO. DESCRIPTION QTY

1401683 Side-Shift Carriage (42 in.) (8503023) ................................................................ 1
1401684 Side-Shift Carriage (48 in.) (8503024) ................................................................ 1
1 1401703 Carriage (Frame) (42 in.) (FFigure 13-17).................................................... 1
1 1401704 Carriage (Frame) (48 in.) (FFigure 13-18).................................................... 1
2 1511883 Load Roller ("B") (104.44/104.18) .................................................................. 6
3 126765 Shim ............................................................................................................... 24
4 1465072 Snap Ring ....................................................................................................... 6
5 1399224 Spacer ............................................................................................................ 2
6 1624590 Chain Anchor .................................................................................................. 2
7 339932 Pin .................................................................................................................. 2
8 1624589 Pin .................................................................................................................. 2
9 15222 Cotter Pin ....................................................................................................... 2
10 131358 Snap Ring ....................................................................................................... 2
11 66333 Roll Pin ........................................................................................................... 2
12 1387993 Side Roller ...................................................................................................... 2
13 16001 Grease Fitting ................................................................................................. 2
14 1465177 Bracket ........................................................................................................... 2
15 192425 Shim (0.062 in.) .............................................................................................. 6
16 192424 Shim (0.030 in.) .............................................................................................. 8
17 1465028 Pin .................................................................................................................. 2
18 292528 Capscrew ....................................................................................................... 4
19 292683 Lockwasher .................................................................................................... 4
20 319322 Bracket Wldmt (RH) ....................................................................................... 1
21 319323 Bracket Wldmt (LH) ........................................................................................ 1
22 317292 Spacer ............................................................................................................ 4
23 18518 Capscrew ....................................................................................................... 4
24 15155 Lockwasher .................................................................................................... 4
25 1516202 Fitting .............................................................................................................. 1
25 265731 O-Ring ........................................................................................................ 1
25 16484 O-Ring ........................................................................................................ 1
26 1473897 Fitting .............................................................................................................. 1
26 265731 O-Ring ........................................................................................................ 1
26 16484 O-Ring ........................................................................................................ 1
27 816591 Fitting (Includes Nut) ...................................................................................... 2
27 265731 O-Ring ........................................................................................................ 2
28 1486772 Fitting .............................................................................................................. 1
28 265731 O-Ring ........................................................................................................ 2
29 2078109 Hose Assy ...................................................................................................... 1
30 2078110 Hose Assy ...................................................................................................... 1

©2011 HYSTER COMPANY See Service Manual 13-29

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT CARRIAGE (FIGURE 13-17)

TWO STAGE FULL FREE-LIFT — 1067 MM (42 IN.) CLASS III

13-30 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT CARRIAGE

TWO STAGE FULL FREE-LIFT – 1067 MM (42 IN.) CLASS III

ITEM PART NO. DESCRIPTION QTY

1401703 Carriage (Frame) (42 in.) .................................................................................... 1
1 1518337 Frame ............................................................................................................. 1
2 1467147 Wear Strip (Right Upper) ................................................................................ 1
3 1467145 Wear Strip (Right Lower) ................................................................................ 1
4 1467148 Wear Strip (Left Upper) .................................................................................. 1
5 16041 Grease Fitting ................................................................................................. 4
6 1622935 Seal ................................................................................................................ 2
7 1467151 Bushing .......................................................................................................... 2
8 1467150 Rod Wiper ...................................................................................................... 2
9 1467632 Snap Ring ....................................................................................................... 2
10 1467153 Rod ................................................................................................................. 2
11 39365 O-Ring ............................................................................................................ 2
12 1467146 Wear Strip (Left Lower) .................................................................................. 2
13 1518330 Apron .............................................................................................................. 1
14 1467154 Hook ............................................................................................................... 2
15 1467633 Screw ............................................................................................................. 6
2083999 Kit-Seal (Class III) (Includes Items 6, 8, 11) ....................................................... 1

©2011 HYSTER COMPANY See Service Manual 13-31

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT CARRIAGE (FIGURE 13-18)

TWO STAGE FULL FREE-LIFT — 1219 MM (48 IN.) CLASS III

13-32 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT CARRIAGE

TWO STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS III

ITEM PART NO. DESCRIPTION QTY

1401704 Carriage (Frame) (48 in.) .................................................................................... 1
1 1518338 Frame ............................................................................................................. 1
2 1467147 Wear Strip (Right Upper) ................................................................................ 1
3 1467145 Wear Strip (Right Lower) ................................................................................ 1
4 1467148 Wear Strip (Left Upper) .................................................................................. 1
5 16041 Grease Fitting ................................................................................................. 8
6 1622935 Seal ................................................................................................................ 2
7 1467151 Bushing .......................................................................................................... 2
8 1467150 Rod Wiper ...................................................................................................... 2
9 1467632 Snap Ring ....................................................................................................... 2
10 1467153 Rod ................................................................................................................. 2
11 39365 O-Ring ............................................................................................................ 2
12 1467146 Wear Strip (Left Lower) .................................................................................. 2
13 1532645 Apron .............................................................................................................. 1
14 1467154 Hook ............................................................................................................... 2
15 1467633 Screw ............................................................................................................. 6
2083999 Kit-Seal (Class III) (Includes Items 6, 8, 11) ....................................................... 1

©2011 HYSTER COMPANY See Service Manual 13-33

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT (FIGURE 13-19)

THREE STAGE FULL FREE-LIFT — S80FT

13-34 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT
THREE STAGE FULL FREE-LIFT – S80FT

ITEM PART NO. DESCRIPTION QTY

1401679 Side-Shift Carriage (42 in.) (8503019) ................................................................ 1
1401680 Side-Shift Carriage (48 in.) (8503020) ................................................................ 1
1 1401699 Carriage (Frame) (42 in.) (FFigure 13-20).................................................... 1
2 1401700 Carriage (Frame) (48 in.) (FFigure 13-21).................................................... 1
2 1624590 Chain Anchor ............................................................................................. 2
3 1624589 Pin (Chain Anchor) ..................................................................................... 2
4 131358 Snap Ring (Chain Anchor Pin) ................................................................... 2
5 1511883 Load Roller ("B") (104.44/104.18) .................................................................. 6
6 126765 Shim ............................................................................................................... 24
7 339932 Pin .................................................................................................................. 2
8 15222 Cotter Pin ....................................................................................................... 2
9 816591 Fitting (Includes Nut) ...................................................................................... 2
9 265731 O-Ring ........................................................................................................ 2
10 1399224 Spacer ............................................................................................................ 2
11 66333 Roll Pin ........................................................................................................... 2
12 1387993 Side Roller ...................................................................................................... 2
12 1670064 Cam Follower (Alternate Part) ........................................................................ 2
13 16001 Grease Fitting ................................................................................................. 2
14 1465177 Bracket ........................................................................................................... 2
15 192425 Shim (0.062 in.) .............................................................................................. AR
16 192424 Shim (0.030 in.) .............................................................................................. AR
17 1465028 Pin .................................................................................................................. 2
17 1670065 Pin (Alternate Part) ......................................................................................... 2
18 292528 Capscrew ....................................................................................................... 4
19 292683 Lockwasher .................................................................................................... 4
20 319322 Bracket Wldmt (RH) ....................................................................................... 1
21 319323 Bracket Wldmt (LH) ........................................................................................ 1
22 317292 Spacer ............................................................................................................ 4
23 1486772 Fitting .............................................................................................................. 1
24 18518 Capscrew ....................................................................................................... 4
25 15155 Lockwasher .................................................................................................... 4
26 1473897 Fitting .............................................................................................................. 1
26 265731 O-Ring ........................................................................................................ 1
26 16484 O-Ring ........................................................................................................ 1
27 1516202 Fitting .............................................................................................................. 1
27 16484 O-Ring ........................................................................................................ 1
27 265731 O-Ring ........................................................................................................ 1
28 2078110 Hose Assy ...................................................................................................... 1
29 2078109 Hose Assy ...................................................................................................... 1
30 1465072 Snap Ring ....................................................................................................... 6

©2011 HYSTER COMPANY See Service Manual 13-35

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT CARRIAGE (FIGURE 13-20)

THREE STAGE FULL FREE-LIFT — 1067 MM (42 IN.) CLASS III

13-36 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT CARRIAGE

THREE STAGE FULL FREE-LIFT – 1067 MM (42 IN.) CLASS III

ITEM PART NO. DESCRIPTION QTY

1401699 Carriage (Frame) (42 in.) .................................................................................... 1
1 1518334 Frame ............................................................................................................. 1
2 1467147 Wear Strip (Right Upper) ................................................................................ 1
3 1467148 Wear Strip (Left Upper) .................................................................................. 1
4 16041 Grease Fitting ................................................................................................. 8
5 1622935 Seal ................................................................................................................ 2
6 1467151 Bushing .......................................................................................................... 2
7 1467150 Rod Wiper ...................................................................................................... 2
8 1467632 Snap Ring ....................................................................................................... 2
9 1467153 Rod ................................................................................................................. 2
10 39365 O-Ring ............................................................................................................ 2
11 1467145 Wear Strip (Right Lower) ................................................................................ 1
12 1467146 Wear Strip (Left Lower) .................................................................................. 1
13 1532644 Apron .............................................................................................................. 2
14 1467154 Hook ............................................................................................................... 2
15 1467633 Screw ............................................................................................................. 6
2083999 Kit-Seal (Class III) (Includes Items 5, 7, 10) ....................................................... 1

©2011 HYSTER COMPANY See Service Manual 13-37

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT CARRIAGE (FIGURE 13-21)

THREE STAGE FULL FREE-LIFT — 1219 MM (48 IN.) CLASS III

13-38 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT CARRIAGE

THREE STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS III

ITEM PART NO. DESCRIPTION QTY

1401700 Carriage (Frame) (48 in.) .................................................................................... 1
1 1518335 Frame ............................................................................................................. 1
2 1467148 Wear Strip (Left Upper) .................................................................................. 1
3 1467147 Wear Strip (Right Upper) ................................................................................ 1
4 1467145 Wear Strip (Right Lower) ................................................................................ 1
5 16041 Grease Fitting ................................................................................................. 4
6 1622935 Seal ................................................................................................................ 2
7 1467151 Bushing .......................................................................................................... 2
8 1467150 Rod Wiper ...................................................................................................... 2
9 1467632 Snap Ring ....................................................................................................... 2
10 1467153 Rod ................................................................................................................. 2
11 39365 O-Ring ............................................................................................................ 2
12 1467146 Wear Strip (Left Lower) .................................................................................. 2
13 1532645 Apron .............................................................................................................. 1
14 1467154 Hook ............................................................................................................... 2
15 1467633 Screw ............................................................................................................. 6
2083999 Kit-Seal (Class III) (Includes Items 6, 8, 11) ....................................................... 1

©2011 HYSTER COMPANY See Service Manual 13-39

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT (FIGURE 13-22)

TWO AND THREE STAGE FULL FREE-LIFT — S100-120FT

13-40 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT
TWO AND THREE STAGE FULL FREE-LIFT – S100-120FT
KEY:
A: Two Stage Full Free-Lift
B: Three Stage Full Free-Lift
QTY
ITEM PART NO. DESCRIPTION A B
1401682 Side-Shift Carriage (48 in.) (8503022) ....................................................... 1 ..
1401686 Side-Shift Carriage (48 in.) (8503026) ....................................................... .. 1
1 1401702 Carriage (Frame) (48 in.) (8503042) (FFigure 13-24).......................... .. 1
1 1401706 Carriage (Frame) (48 in.) (8503046) (FFigure 13-23).......................... 1 ..
2 339932 Pin .......................................................................................................... 2 2
3 15222 Cotter Pin ............................................................................................... 2 2
4 1511883 Load Roller ("B") (104.44/104.18) .......................................................... 6 6
5 1399224 Spacer ................................................................................................... 2 2
6 1465072 Snap Ring .............................................................................................. 6 6
7 15155 Lockwasher ............................................................................................ 4 4
8 18520 Capscrew ............................................................................................... 3 3
9 1387993 Side Roller ............................................................................................. 2 2
9 1670064 Cam Follower (Alternate Part) ............................................................... 2 2
10 192425 Shim (0.062 in.) ..................................................................................... AR AR
11 192424 Shim (0.030 in.) ..................................................................................... AR AR
12 18518 Capscrew ............................................................................................... 1 1
13 1465028 Pin .......................................................................................................... 2 2
13 1670065 Pin (Alternate Part) ................................................................................ 2 2
14 317292 Spacer ................................................................................................... 4 4
15 66333 Roll Pin .................................................................................................. 2 2
16 1465177 Bracket ................................................................................................... 2 2
17 292528 Capscrew ............................................................................................... 4 4
18 292683 Lockwasher ............................................................................................ 4 4
19 16001 Grease Fitting ........................................................................................ 2 2
20 319323 Bracket Wldmt (LH) ............................................................................... 1 1
21 319322 Bracket Wldmt (RH) ............................................................................... 1 1
22 126765 Shim ....................................................................................................... 6 6
23 16559 Fitting ..................................................................................................... 1 1
23 265731 O-Ring ............................................................................................... 1 1
23 16484 O-Ring ............................................................................................... 1 1
24 2078112 Hose Assy .............................................................................................. 1 1
25 2078111 Hose Assy .............................................................................................. 1 1
26 16541 Fitting ..................................................................................................... 1 1
26 265731 O-Ring ............................................................................................... 1 1
26 16484 O-Ring ............................................................................................... 1 1
27 1528580 Fitting (Includes Nut) .............................................................................. 2 2
27 265731 O-Ring ............................................................................................... 2 2

©2011 HYSTER COMPANY See Service Manual 13-41

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT CARRIAGE (FIGURE 13-23)

TWO STAGE FULL FREE-LIFT — 1219 MM (48 IN.) CLASS IV

13-42 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT CARRIAGE

TWO STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS IV

ITEM PART NO. DESCRIPTION QTY

1401706 Carriage (Frame) (48 in.) .................................................................................... 1
1 1518345 Frame ............................................................................................................. 1
2 1467147 Wear Strip (Right Upper) ................................................................................ 2
3 1467200 Wear Strip ...................................................................................................... 1
4 1467148 Wear Strip (Left Upper) .................................................................................. 1
5 1467145 Wear Strip (Right Lower) ................................................................................ 1
6 16041 Grease Fitting ................................................................................................. 8
7 1622936 Seal ................................................................................................................ 2
8 1467204 Bushing .......................................................................................................... 2
9 1467203 Rod Wiper ...................................................................................................... 2
10 1467634 Snap Ring ....................................................................................................... 2
11 1467205 Rod ................................................................................................................. 2
12 39366 O-Ring ............................................................................................................ 2
13 1624590 Chain Anchor .................................................................................................. 2
14 1467146 Wear Strip (Left Lower) .................................................................................. 1
15 1624589 Pin .................................................................................................................. 2
16 131358 Snap Ring ....................................................................................................... 2
17 1467201 Wear Strip ...................................................................................................... 2
18 1532637 Apron .............................................................................................................. 1
19 1467206 Hook ............................................................................................................... 2
20 1467633 Screw ............................................................................................................. 8
2083999 Kit-Seal (Class III) (Includes Items 7, 9, 12) ....................................................... 1

©2011 HYSTER COMPANY See Service Manual 13-43

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

INTEGRAL SIDE-SHIFT CARRIAGE (FIGURE 13-24)

THREE STAGE FULL FREE-LIFT — 1219 MM (48 IN.) CLASS IV

13-44 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

INTEGRAL SIDE-SHIFT CARRIAGE

THREE STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS IV

ITEM PART NO. DESCRIPTION QTY

1401702 Carriage (Frame) (48 in.) .................................................................................... 1
1 1518344 Frame ............................................................................................................. 1
2 1467200 Wear Strip ...................................................................................................... 2
3 1467147 Wear Strip (Right Upper) ................................................................................ 1
4 1467145 Wear Strip (Right Lower) ................................................................................ 1
5 1467148 Wear Strip (Left Upper) .................................................................................. 1
6 16041 Grease Fitting ................................................................................................. 8
7 1622936 Seal ................................................................................................................ 2
8 1467204 Bushing .......................................................................................................... 2
9 1467203 Rod Wiper ...................................................................................................... 2
10 39366 O-Ring ............................................................................................................ 2
11 1467205 Rod ................................................................................................................. 2
12 1467201 Wear Strip ...................................................................................................... 2
13 1467146 Wear Strip (Left Lower) .................................................................................. 1
14 1532637 Apron .............................................................................................................. 1
15 1467634 Snap Ring ....................................................................................................... 2
16 1467206 Hook ............................................................................................................... 2
17 1467633 Screw ............................................................................................................. 8
2083998 Kit-Seal (Class IV) (Includes Items 7, 9-10) ........................................................ 1

©2011 HYSTER COMPANY See Service Manual 13-45

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NOTES

13-46 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

14 FIELD CONVERSION KITS

 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 14
FIELD CONVERSION KITS

DESCRIPTION PAGE

ADD-ON OPTION KITS ................................................................................................................................... 14-2

AUDIBLE ALARM KITS ................................................................................................................................... 14-3
AUXILIARY TUBE EXTENSION KIT ............................................................................................................... 14-9
BRAKE AND INCHING PEDAL CONVERSION .............................................................................................. 14-2
E-HYDRAULIC CONTROL CONVERSION KITS
→ S/N G004V04679H INC. 04683 ............................................................................................................. 14-3
S/N G004V04679H → EXC. 04683 ............................................................................................................ 14-4
HEADER HOSE CONVERSION KITS
THREE STAGE FULL FREE-LIFT .............................................................................................................. 14-8
TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-7
TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 14-6
LIGHT KITS ..................................................................................................................................................... 14-3
MANUAL HYDRAULIC CONTROL CONVERSION KITS ............................................................................... 14-4
MISCELLANEOUS .......................................................................................................................................... 14-11
REPLACEMENT KITS
E. HYDRAULIC CONTROL VALVES - WITH ANTI-STALL ........................................................................ 14-10
SEAT CONVERSION KITS ............................................................................................................................. 14-2

©2011 HYSTER COMPANY See Service Manual 14-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

SEAT CONVERSION KITS

DESCRIPTION PART NUMBER

Kit-Swivel Seat Full Susp (Vinyl w/o E-Hyd Controls) 1587556
Kit-Swivel Seat Full Susp (Cloth w/o E-Hyd Controls) 1587557
Kit-Swivel Seat Full Susp (Vinyl with E-Hyd Controls) 1587558
Kit-Swivel Seat Full Susp (Cloth with E-Hyd Controls) 1587559
Kit-Seat-Full Susp Non-Swivel (Vinyl w/o E-Hyd Controls) (FLM) 4016015
Kit-Seat-Full Susp Non-Swivel (Cloth w/o E-Hyd Controls) (FLM) 4016016
Kit-Seat-Full Susp Non-Swivel (Vinyl with E-Hyd Controls) (FLM) 4016019
Kit-Seat-Full Susp Non-Swivel (Cloth with E-Hyd Controls) (FLM) 4016020
Kit-Seat-Full Susp Swivel (Vinyl w/o E-Hyd Controls) (FLM) 4016017
Kit-Seat-Full Susp Swivel (Cloth w/o E-Hyd Controls) (FLM) 4016018
Kit-Seat-Full Susp Swivel (Vinyl with E-Hyd Controls) (FLM) 4016021
Kit-Seat-Full Susp Swivel (Cloth with E-Hyd Controls) (FLM) 4016022
Kit-Red Seat Belt 1636120

BRAKE AND INCHING PEDAL CONVERSION

DESCRIPTION PART NUMBER

Kit-Dual Brake Pedal 1619985
Kit-Dual Brake Pedal 1619986
Kit-Dual Brake Pedal 1619987

ADD-ON OPTION KITS

DESCRIPTION PART NUMBER

Kit-Keyswitch to Pushbutton (Pushbutton Start with Remote Key Switch) 1624521
Kit-Powertrain Protection (English - US Language) 1585854
Kit-Air Intake W Pre-Cleaner 1583815
Kit-Mirror (With Overhead Guard) 1581968
Kit-Impact Monitoring (With Immediate Shutdown) 1629135
Kit-Impact Monitoring (With 30 Second Shutdown) 1637768
Kit-Fire Extinguisher (W/o Cab) 1650586
Kit-Fire Extinguisher (With Cab) 1635618
Kit-Stubshaft 1654694
Kit-Oil Cooler 1660082
Kit-Oil Cooler 1660083
Kit-Oil Cooler 1660084
Kit (Radiator Screen) 1695636
Kit-Sensor (Low LPG Fuel) (Pre-2010 GM) 4007943

14-2 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

ADD-ON OPTION KITS (CONTINUED)

DESCRIPTION PART NUMBER

Kit-Sensor (Low LPG Fuel) (2010 GM) 1714451

LIGHT KITS

DESCRIPTION PART NUMBER

Kit-Light (Halogen Front Drive/Rear Work Light, with Harness and Overhead Guard) 1583707
Kit-Light (Front Drive/Rear Work lights, w/o Harness, with Overhead Guard) 1583708
Kit-Light (Brake/Tail/Back-up Lights with Harness, with Overhead Guard) 1583711
Kit-Light (Brake/Tail/Back-up Lights w/o Harness with Overhead Guard) 1583712
Kit-Light (Strobe -Flash Tube with Other Lights and Overhead Guard, with Harness) 1583709
Kit-Light (Strobe, Flash Tube with Other Lights and Overhead Guard, w/o Harness) 1583710
Kit-Light (LED Strobe w/o Other Lights for Overhead Guard with Harness) 1655204
Kit-Light (LED Strobe with other lights for Overhead Guard, w/o Harness) 1655205
Kit-Front Drive/Rear Worklight (LED w/o Other Lights for Overhead Guard with 1700244
Harness)
Kit-Front Drive/Rear Worklight (LED with other lights for Overhead Guard, w/o 1700245
Harness)

AUDIBLE ALARM KITS

DESCRIPTION PART NUMBER

Kit-Back-Up Alarm (87 DB(A)) 1626367
Kit-Back-Up Alarm (97 DB(A)) 1626368
Kit-Back-Up Alarm (102 DB(A)) 1626369
Kit-Back-Up Alarm (107 DB(A)) 1626370
Kit-Back-Up Alarm (82-102 DB(A)) 1626371
Kit-Back-Up Alarm (87 DB(A) w/o cab AM) 4003206
Kit-Back-Up Alarm (97 DB(A) w/o Cab AM) 4003207
Kit-Back-Up Alarm (102 DB(A) w/o Cab AM) 4003208
Kit-Back-Up Alarm (107 DB(A) w/o Cab AM) 4003209
Kit-Back-Up Alarm (82-102 DB(A) w/o Cab AM) 4003210
Kit-Back-Up Alarm (87 DB(A) With Cab AM) 4003211
Kit-Back-Up Alarm (97 DB(A) With Cab AM) 4003212
Kit-Back-Up Alarm (102 DB(A) With Cab AM) 4003213
Kit-Back-Up Alarm (107 DB(A) With Cab AM) 4003214
Kit-Back-Up Alarm (82-102 DB(A) With Cab AM) 4003215

E-HYDRAULIC CONTROL CONVERSION KITS

(→ S/N G004V04679H INC. 04683)

©2011 HYSTER COMPANY See Service Manual 14-3

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

E-HYDRAULIC CONTROL CONVERSION KITS

(→ S/N G004V04679H INC. 04683)
(CONTINUED)

DESCRIPTION PART NUMBER

Kit-Mini Lever Conv 3 Way (without Clamp to 3 Way with Clamp) a1585281
Kit-Mini Lever Conv 3 Way (With Clamp to 3 Way Without Clamp) a1607685
Kit-Mini Lever Conv 3 Way (without Clamp to 4 Way without Clamp) a1633676
Kit-Mini Lever Conv 3 Way (without Clamp to 4 Way with Clamp) a1633677
Kit-Mini Lever Conv 4 Way (With Clamp to 4 Way Without Clamp) a1635699
Kit-Mini Lever Conv 3 Way (without Clamp to 5 Way without Clamp) a1633678
Kit-Mini Lever Conv 3 Way (without Clamp to 5 Way with Clamp) a1633679
Kit-Mini Lever Conv 4 Way (without Clamp to 4 Way with Clamp) a1703633

FOOTNOTES:
a Kit requires Software that must be Dealer installed.

E-HYDRAULIC CONTROL CONVERSION KITS

(S/N G004V04679H → EXC. 04683)

DESCRIPTION PART NUMBER

Kit-Mini Lever Conv 3 Way (without Lockout to with Lockout) a1701683
Kit-Mini Lever Conv 3 Way (with Lockout to without Lockout) a1701682
Kit-Mini Lever Conv 3 Way (without Clamp to 4 Way without Clamp) a4014410
Kit-Mini Lever Conv 3 Way (without Clamp to 4 Way with Clamp) a4014411
Kit-Mini Lever Conv 3 Way (without Clamp to 5 Way with Clamp) a4014412
Kit-Mini Lever Conv 4 Way (with Lockout to without Lockout) a1701684
Kit-Mini Lever Conv 4 Way (without Lockout to with Lockout) a1701685

FOOTNOTES:
a Kit requires Software that must be Dealer installed.

MANUAL HYDRAULIC CONTROL CONVERSION KITS

DESCRIPTION PART NUMBER

Kit-Manual Lever Conv 3 Way (without Clamp to 3 Way with Clamp) b1584061
Kit-Manual Lever Conv 3 Way (without Clamp to 4 Way without Clamp) a1633945
Kit-Manual Lever Conv 3 Way (without Clamp to 4 Way without Clamp) c1670824
Kit-Manual Lever Conv 3 Way (without Clamp to 4 Way with Clamp) a1633943
Kit-Manual Lever Conv 3 Way (without Clamp to 4 Way with Clamp) c1670826
Kit-Manual Lever Conv 3 Way (without Clamp to 3 Way with Clamp) d1677913
Kit-Manual Lever Conv 3 Way (without Clamp to 4 Way without Clamp) d1678505
Kit-Manual Lever Conv 3 Way (without Clamp to 4 Way with Clamp) d1678502

FOOTNOTES:

14-4 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

a → S/N G004V02934E
b → S/N G004V03263F EXC. 03240-03242, 03244-03247
c S/N G004V02935E ↔ S/N G004V03263F EXC. 03240-03242, 03244-03247
d S/N G004V03264F → INC. 03240-03242, 03244-03247

©2011 HYSTER COMPANY See Service Manual 14-5

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HEADER HOSE CONVERSION KITS

TWO STAGE LIMITED FREE-LIFT

HEADER HOSE CONVERSION KITS TWO STAGE LIMITED FREE-LIFT

LIFT HEIGHT TO BOTTOM OF FORKS

2740 mm 3000 mm 3340 mm 3600 mm 3940 mm
DESCRIPTION (107.9 in.) (118.1 in.) (131.5 in.) (141.7 in.) (155.1 in.)
Mast B587 B586 B587 B586 B587
Group Number 2740 3000 3340 3600 3940
Kit-Hose Group 2 to 3 1625294 1625286 1625298 1625290 1625302
Way

HEADER HOSE CONVERSION KITS TWO STAGE LIMITED FREE-LIFT

LIFT HEIGHT TO BOTTOM OF FORKS

2740 mm 3000 mm 3340 mm 3600 mm 3940 mm
DESCRIPTION (107.9 in.) (118.1 in.) (131.5 in.) (141.7 in.) (155.1 in.)
Mast B587 B586 B587 B586 B587
Group Number 2740 3000 3340 3600 3940
Kit-Hose Group 2 to 4 1625296 1625288 1625300 1625292 1625304
Way

HEADER HOSE CONVERSION KITS TWO STAGE LIMITED FREE-LIFT

LIFT HEIGHT TO BOTTOM OF FORKS

2740 mm 3000 mm 3340 mm 3600 mm 3940 mm
DESCRIPTION (107.9 in.) (118.1 in.) (131.5 in.) (141.7 in.) (155.1 in.)
Mast B587 B586 B587 B586 B587
Group Number 2740 3000 3340 3600 3940
Kit-Hose Group 3 to 4 1625295 1625287 1625299 1625291 1625303
Way

HEADER HOSE CONVERSION KITS TWO STAGE LIMITED FREE-LIFT

LIFT HEIGHT TO BOTTOM OF FORKS

2740 mm 3000 mm 3340 mm 3600 mm 3940 mm
DESCRIPTION (107.9 in.) (118.1 in.) (131.5 in.) (141.7 in.) (155.1 in.)
Mast B587 B586 B587 B586 B587
Group Number 2740 3000 3340 3600 3940
Kit-Hose Group 4 to 5 1625297 1625289 1625301 1625293 1625305
Way

14-6 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

HEADER HOSE CONVERSION KITS

TWO STAGE FULL FREE-LIFT

HEADER HOSE CONVERSION KITS TWO STAGE FULL FREE-LIFT

LIFT HEIGHT TO BOTTOM OF FORKS

2765 mm 3365 mm
DESCRIPTION (108.9 in.) (132.5 in.)
Mast B591 B591
Group Number 2765 3365
Kit-Hose Group 2 to 3 1626009 1626013
Way

HEADER HOSE CONVERSION KITS TWO STAGE FULL FREE-LIFT

LIFT HEIGHT TO BOTTOM OF FORKS

2765 mm 3365 mm
DESCRIPTION (108.9 in.) (132.5 in.)
Mast B591 B591
Group Number 2765 3365
Kit-Hose Group 2 to 4 1626011 1626015
Way

HEADER HOSE CONVERSION KITS TWO STAGE FULL FREE-LIFT

LIFT HEIGHT TO BOTTOM OF FORKS

2765 mm 3365 mm
DESCRIPTION (108.9 in.) (132.5 in.)
Mast B591 B591
Group Number 2765 3365
Kit-Hose Group 3 to 4 1626010 1626014
Way

HEADER HOSE CONVERSION KITS TWO STAGE FULL FREE-LIFT

LIFT HEIGHT TO BOTTOM OF FORKS

2765 mm 3365 mm
DESCRIPTION (108.9 in.) (132.5 in.)
Mast B591 B591
Group Number 2765 3365
Kit-Hose Group 4 to 5 1626012 1626016
Way

©2011 HYSTER COMPANY See Service Manual 14-7

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

HEADER HOSE CONVERSION KITS

THREE STAGE FULL FREE-LIFT

FOUR TO FIVE FUNCTION

LIFT HEIGHT TO BOTTOM OF FORKS

4087 mm 4365 mm 4640 mm 4665 mm
DESCRIPTION (160.9 in.) (171.9 in.) (182.7 in.) (183.7 in.)
Mast B589 B588 B589 B588
Group Number 4087 4365 4640 4665
Kit-Hose Group 4 to 5 1626675 1626659 1626679 1626663
Way

FOUR TO FIVE FUNCTION

LIFT HEIGHT TO BOTTOM OF FORKS

4900 mm 5240 mm 5500 mm
DESCRIPTION (192.9 in.) (206.3 in.) (216.5 in.)
Mast B588 B589 B588
Group Number 4900 5240 5500
Kit-Hose Group 4 to 5 1626667 1626683 1626671
Way

THREE TO FOUR FUNCTION

LIFT HEIGHT TO BOTTOM OF FORKS

4087 mm 4365 mm 4640 mm 4665 mm
DESCRIPTION (160.9 in.) (171.9 in.) (182.7 in.) (183.7 in.)
Mast B589 B588 B589 B588
Group Number 4087 4365 4640 4665
Kit-Hose Group 3 to 4 1626673 1626657 1626677 1626661
Way

THREE TO FOUR FUNCTION

LIFT HEIGHT TO BOTTOM OF FORKS

4900 mm 5240 mm 5500 mm
DESCRIPTION (192.9 in.) (206.3 in.) (216.5 in.)
Mast B588 B589 B588
Group Number 4900 5240 5500
Kit-Hose Group 3 to 4 1626665 1626681 1626669
Way

14-8 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

TWO TO FOUR FUNCTION

LIFT HEIGHT TO BOTTOM OF FORKS

4087 mm 4365 mm 4640 mm 4665 mm
DESCRIPTION (160.9 in.) (171.9 in.) (182.7 in.) (183.7 in.)
Mast B589 B588 B589 B588
Group Number 4087 4365 4640 4665
Kit-Hose Group 2 to 4 1626674 1626658 1626678 1626662
Way

TWO TO FOUR FUNCTION

LIFT HEIGHT TO BOTTOM OF FORKS

4900 mm 5240 mm 5500 mm
DESCRIPTION (192.9 in.) (206.3 in.) (216.5 in.)
Mast B588 B589 B588
Group Number 4900 5240 5500
Kit-Hose Group 2 to 4 1626666 1626682 1626670
Way

TWO TO THREE FUNCTION

LIFT HEIGHT TO BOTTOM OF FORKS

4087 mm 4365 mm 4640 mm 4665 mm
DESCRIPTION (160.9 in.) (171.9 in.) (182.7 in.) (183.7 in.)
Mast B589 B588 B589 B588
Group Number 4087 4365 4640 4665
Kit-Hose Group 2 to 3 1626672 1626656 1626676 1626660
Way

TWO TO THREE FUNCTION

LIFT HEIGHT TO BOTTOM OF FORKS

4900 mm 5240 mm 5500 mm
DESCRIPTION (192.9 in.) (206.3 in.) (216.5 in.)
Mast B588 B589 B588
Group Number 4900 5240 5500
Kit-Hose Group 2 to 3 1626664 1626680 1626668
Way

AUXILIARY TUBE EXTENSION KIT

DESCRIPTION PART NUMBER

Kit-Quick Disconnect Fitting 1650605
Kit-Aux Tube Extension (3 Function, Class III Std Carriage, 2 Stg LFL) 1639773
Kit-Aux Tube Extension (4 Function, Class III Std Carriage, 2 Stg LFL) 1639774
Kit-Aux Tube Extension (3 Function, Class IV, Std Carriage, 2 Stg LFL) 1639775

©2011 HYSTER COMPANY See Service Manual 14-9

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

AUXILIARY TUBE EXTENSION KIT (CONTINUED)

DESCRIPTION PART NUMBER

Kit-Aux Tube Extension (4 Function, Class IV, Std Carriage, 2 Stg LFL) 1639776
Kit-Aux Tube Extension (3 Function, Class III Integral Side-Shift Carriage, 2 Stg LFL) 1639777
Kit-Aux Tube Extension (4 Function, Class III Integral Side-Shift Carriage, 2 Stg LFL) 1639778
Kit-Aux Tube Extension (3 Function, Class IV, Integral Side-Shift Carriage, 2 Stg LFL) 1639779
Kit-Aux Tube Extension (4 Function, Class IV, Integral Side-Shift Carriage, 2 Stg LFL) 1639780
Kit-Aux Tube Extension (3 Function, Class III, Attachment Carriage, 2 LFL) 1639781
Kit-Aux Tube Extension (4 Function, Class III, Attachment Carriage, 2 LFL) 1639782
Kit-Aux Tube Extension (3 Function, Class III Integral Side-Shift Carriage, 2 Stg FFL) 1641801
Kit-Aux Tube Extension (3 Function, Class IV, Std Carriage, 2 Stg FFL) 1641803
Kit-Aux Tube Extension (3 Function, Class III, Integral Side-Shift Carriage, 2 Stg FFL) 1641802
Kit-Aux Tube Extension (3 Function, Class IV, Integral Side-Shift Carriage, 2 FFL) 1641805
Kit-Aux Tube Extension (3 Function, Class III, Attachment Carriage, 2 Stg FFL) 1641804
Kit-Aux Tube Extension (3 Function, Class III Std Carriage, 3 Stg FFL) 1641808
Kit-Aux Tube Extension (4 Function, Class III Std Carriage, 3 Stg FFL) 1641810
Kit-Aux Tube Extension (3 Function, Class IV, Std Carriage, 3 Stg FFL) 1643206
Kit-Aux Tube Extension (4 Function, Class IV Std Carriage, 3 Stg FFL) 1643207
Kit-Aux Tube Extension (3 Function, Class III Integral Side-Shift Carriage, 3 Stg FFL) 1643208
Kit-Aux Tube Extension (4 Function, Class III Integral Side-Shift Carriage, 3 Stg FFL) 1643209
Kit-Aux Tube Extension (3 Function, Class IV, Integral Side-Shift Carriage, 3 Stg FFL) 1643210
Kit-Aux Tube Extension (4 Function, Class IV, Integral Side-Shift Carriage, 3 Stg FFL) 1643211
Kit-Aux Tube Extension (3 Function, Class III Attachment Carriage, 3 Stg FFL) 1643212
Kit-Aux Tube Extension (4 Function, Class III, Attachment Carriage, 3 Stg FFL) 1643213
Kit (E-Hydraulic QD Fittings, Single Aux) 4010077
Kit (E-Hydraulic QD Fittings, Dual Aux) 4010078
Kit (E-Hydraulic QD Fittings, Single Aux) 4010095
Kit (E-Hydraulic QD Fittings, Single Aux) 4010096
Kit (E-Hydraulic QD Fittings, Dual Aux) 4010097
Kit (E-Hydraulic QD Fittings, Single Aux) 4010098

REPLACEMENT KITS
E. HYDRAULIC CONTROL VALVES
WITH ANTI-STALL

DESCRIPTION PART NUMBER

Kit-Hyd Control Valve (3 Function with Steering Control Unit) 4000634
Kit-Hyd Control Valve (4 Function with Steering Control Unit) 4000636
Kit-Hyd Control Valve (5 Function with Steering Control Unit) 4000638
Kit-Hyd Control Valve (3 Function without Steering Control Unit) 4000639

14-10 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

REPLACEMENT KITS
E. HYDRAULIC CONTROL VALVES
WITH ANTI-STALL
(CONTINUED)

DESCRIPTION PART NUMBER

Kit-Hyd Control Valve (4 Function without Steering Control Unit) 4000640
Kit-Hyd Control Valve (5 Function without Steering Control Unit) 4000641

MISCELLANEOUS

DESCRIPTION PART NUMBER

Kit-Service (Lock-Out Rod 50 DIA Rods) 1665701
Kit-Fwd/Rev Lever to Monotrol 1625467
Kit-Monotrol to Fwd/Rev Lever 1583198
Kit-Mini Lever Conv 4 Way 1703633
Kit-Gas Spring (And Ball Stud) 4016355
Kit-Gas Spring (And Ball Stud) 4016356

©2011 HYSTER COMPANY See Service Manual 14-11

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NOTES

14-12 See Service Manual ©2011 HYSTER COMPANY

for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

15 NUMERICAL INDEX
 UNIT CODE G004
05/2009 NORTH AMERICA

SECTION 15
NUMERICAL INDEX

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

126 4-11 2 5-59 13 16078 4-7 31 5-65 11

206 8-11 19 15180 2-25 6 16134 3-14 31 5-69 15
8-19 19 15222 10-8 34 3-25 33 5-69 21
12856 3-9 11 10-21 8 3-25 33 8-7 32
12891 10-7 18 11-8 26 3-33 41 8-11 32
12-9 13 11-12 26 3-33 41 8-27 3
12921 2-25 8 11-31 12 16151 3-13 13 8-27 5
12929 8-11 20 12-3 12 16480 9-27 14 8-29 3
8-19 20 12-7 8 9-29 12 8-29 11
13957 7-9 17 12-22 29 9-31 14 8-29 17
13963 7-9 3 12-33 12 16481 5-59 18 9-3 4
14349 3-13 13 13-21 3 5-73 3 10-7 20
14358 3-13 12 13-29 9 8-8 38 10-8 24
3-25 34 13-35 8 8-8 44 10-17 19
3-34 43 13-41 3 8-8 49 10-23 8
14372 3-13 10 15224 10-21 10 8-12 38 10-23 12
14385 2-9 21 12-7 10 8-12 50 10-23 14
2-13 21 15235 7-9 9 8-12 55 10-25 5
2-17 10 15241 6-3 12 8-15 37 10-25 8
2-21 15347 3-19 16 8-16 39 10-25 12
14387 2-37 2 15879 10-13 3 8-20 42 11-3 12
14591 9-7 4 12-18 8 8-20 44 11-3 15
14595 10-7 20 15884 9-67 7 8-27 21 11-28 34
11-3 15 15885 11-20 11 8-29 18 11-33 2
12-14 23 11-23 11 9-7 4 11-33 5
14603 5-15 40 12-26 11 13-17 2 11-33 8
10-8 23 15916 4-11 5 16483 7-13 6 12-13 20
11-3 14 15931 3-39 11 8-7 30 12-14 23
14604 6-3 13 16001 9-65 7 8-7 35 12-30 38
15002 4-11 6 10-21 19 8-11 30 12-37 9
15052 4-7 14 11-31 23 8-11 35 12-37 13
15055 9-36 2 12-34 23 8-27 1 12-37 14
9-61 4 13-21 10 8-27 18 13-15 17
9-63 4 13-29 13 8-29 8 13-21 19
15127 1-25 21 13-35 13 8-29 9 13-21 22
15135 5-15 11 13-41 19 10-8 33 13-29 25
5-21 11 16002 10-3 5 10-31 5 13-29 26
5-53 12 11-4 44 11-39 19 13-35 26
5-59 12 12-3 19 12-13 3 13-35 27
15155 11-31 19 16009 7-9 33 12-45 5 13-41 23
12-33 19 16041 13-23 4 13-15 21 13-41 26
13-29 24 13-25 4 16484 5-7 1 16485 5-7 8
13-35 25 13-27 6 5-9 1 5-7 9
13-41 7 13-31 5 5-9 15 5-9 8
15156 4-11 7 13-33 5 5-16 48 5-9 8
11-28 32 13-37 4 5-21 40 5-9 9
15158 5-15 10 13-39 5 5-22 48 5-9 9
5-21 10 13-43 6 5-53 8 5-9 14
5-53 13 13-45 6 5-59 8 5-11 3

©2011 HYSTER COMPANY See Service Manual 15-1

for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

5-11 4 8-20 46 18471 1-40 21 5-43 2

5-13 3 8-29 17 1-47 23 5-45 22
5-13 3 8-29 17 18508 4-53 6 5-47 2
5-13 4 16541 10-23 14 18518 11-31 18 5-49 2
5-15 5 10-25 5 12-33 18 5-51 2
5-15 38 11-28 34 13-29 23 43209 5-15 20
5-16 44 11-33 4 13-35 24 5-19 16
5-21 5 12-37 12 13-41 12 5-21 20
5-21 38 13-41 26 18520 11-31 18 5-25 16
5-22 44 16543 12-14 21 13-41 8 5-27 29
5-53 6 16559 13-41 23 18595 5-15 9 5-53 15
5-53 18 16634 2-33 11 5-21 9 5-57 18
5-53 40 16682 5-15 32 5-53 14 5-59 15
5-59 6 5-21 32 5-59 14 5-61 18
5-59 40 5-31 5 18735 1-39 9 5-65 36
5-60 42 5-57 10 18738 1-39 9 5-69 11
5-65 30 5-61 10 1-47 19 43883 3-9 10
5-65 31 5-65 16 18748 9-25 3 44306 5-53 34
5-66 40 16706 9-27 6 18909 9-3 12 5-59 34
5-73 9 9-29 19 19901 1-33 11 5-69 13
11-4 24 9-31 6 1-40 15 44307 5-19 18
16486 5-15 41 9-33 3 19926 13-15 8 5-25 18
5-16 47 9-35 3 21110 7-9 10 5-27 27
5-21 39 16708 3-39 14 21420 6-3 15 5-57 21
5-54 41 16863 3-13 7 28584 13-17 4 5-62 21
5-54 43 3-25 34 30147 7-10 45 5-65 37
5-54 47 3-34 43 30370 2-3 2 44309 5-15 25
5-59 41 16865 3-39 16 34507 3-23 19 5-21 25
5-65 2 16870 11-28 31 3-25 16 5-27 42
5-69 29 16982 10-7 22 3-29 2 5-53 32
8-7 33 11-4 21 3-33 19 5-59 32
8-11 33 11-4 31 39348 11-20 15 5-69 8
8-27 15 16983 5-19 12 11-24 15 44310 5-15 35
8-29 25 5-25 12 12-26 15 5-21 35
9-3 7 5-57 17 39365 13-23 10 5-31 1
9-3 18 5-61 17 13-25 10 5-57 3
9-3 25 5-69 39 13-31 11 5-61 3
10-8 23 6-4 43 13-33 11 5-66 39
11-3 14 9-3 21 13-37 10 44317 6-21 4
12-14 21 9-3 28 13-39 11 44542 7-10 47
13-15 15 17221 8-27 18 39366 13-27 10 46629 11-20 11
13-15 16 17223 5-13 9 13-43 12 11-23 11
16487 5-16 47 17314 3-13 10 13-45 10 12-26 11
5-22 47 17353 3-9 12 39678 7-9 29 53162 3-39 17
5-54 47 17407 4-11 8 40667 10-5 7 56997 7-10 41
5-60 47 17735 6-3 14 12-9 12 57664 10-11 3
6-3 13 17758 8-27 15 12-21 21 12-18 8
8-7 23 8-29 25 43207 5-33 22 58902 11-28 14
8-8 45 18094 9-15 6 5-35 2 12-29 8
8-12 51 9-19 6 5-37 21 58903 7-9 21
8-12 56 18462 1-40 20 5-39 20 58943 6-21 5
8-15 38 1-47 22 5-41 2 66333 10-21 12
15-2 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

11-31 22 104506 10-3 13 11-31 15 5-27 21

12-34 22 11-4 37 12-3 4 5-57 4
13-21 9 12-3 9 12-7 4 5-61 4
13-29 11 12-9 10 12-9 5 5-65 17
13-35 11 110178 9-72 6 12-33 15 146540 13-9 1
13-41 15 10-8 33 13-21 16 147973 7-15 6
69029 7-9 39 10-31 5 13-29 3 148614 4-105 7
69392 13-17 3 11-39 19 13-35 6 4-108 27
77186 8-8 45 12-13 3 13-41 22 4-111 12
8-12 56 12-45 5 127045 7-9 18 4-115 14
8-29 17 13-15 21 129886 4-108 28 4-118 28
77441 9-33 6 112385 8-7 34 4-112 35 4-122 28
9-35 6 8-11 34 4-118 20 148615 4-105 9
9-55 3 8-29 7 4-122 23 4-115 15
9-59 3 112989 3-3 4 130845 2-53 16 148789 4-7 31
77442 9-27 3 3-5 4 3-13 16 148792 4-7 1
9-29 16 114312 8-8 5-9 16 4-11 3
9-31 3 8-12 5-13 6 148796 4-7 31
9-33 7 8-16 131358 11-31 21 148962 4-55 2
9-35 7 8-20 12-34 21 5-27 36
9-51 3 115696 3-3 6 13-29 10 5-65 14
9-53 4 3-5 6 13-35 4 5-69 35
9-55 4 117989 8-8 47 13-43 16 152404 12-3 14
9-57 4 8-12 53 131715 12-9 8 153070 4-7 1
9-59 4 8-15 35 131716 12-9 7 4-7 31
77443 9-27 5 8-19 41 132861 9-3 30 6-4 38
9-29 17 118358 7-15 7 132972 4-105 13 153715 7-9 7
9-31 5 119236 2-9 14 4-111 6 153716 7-9 5
9-33 8 2-13 14 133696 2-34 44 153717 7-9 8
9-35 8 2-17 13 2-50 28 153834 7-10 44
9-51 4 2-21 9 134810 4-123 1 153835 7-10 43
9-53 5 3-9 23 4-123 9 154066 1-63 19
9-55 5 7-9 20 135657 7-9 27 154067 1-63 19
9-57 5 124603 5-33 16 135658 7-9 28 155671 13-15 12
9-59 5 5-35 17 136681 5-27 15 159971 2-43
78561 13-15 12 5-37 16 5-65 9 159977 2-43 14
86229 5-15 19 5-39 16 6-5 70 161003 11-7 13
5-21 19 5-41 16 136692 10-17 14 11-11 10
5-31 10 5-43 16 11-28 38 12-22 24
5-53 11 5-45 17 12-30 42 161272 10-3 15
5-59 11 5-47 17 136985 5-19 8 11-4 39
5-69 33 5-49 17 5-25 8 12-3 7
97999 3-13 3 5-51 17 5-31 2 161273 10-3 14
3-25 36 125347 3-17 6 5-57 8 11-4 38
3-34 45 126764 10-5 6 5-61 8 12-3 6
101809 3-23 15 12-9 12 5-65 35 164289 8-7 34
3-25 5 12-21 20 141331 3-7 5 8-11 34
3-29 28 126765 10-5 4 142247 10-7 7 8-29 7
3-33 9 10-21 3 11-3 6 164488 2-38 19
104264 10-3 16 11-4 34 12-13 6 164632 11-20 10
11-4 36 11-7 9 145481 5-19 2 11-23 10
12-3 8 11-11 7 5-25 2 12-26 10
©2011 HYSTER COMPANY See Service Manual 15-3
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

164639 7-10 48 185858 7-9 30 12-34 24 5-54 47

166659 11-16 13 185869 7-9 19 13-21 13 5-69 29
166857 3-9 1 185872 7-9 16 13-29 15 222456 13-15 16
8-8 43 187388 11-20 7 13-35 15 222491 8-8 49
8-11 18 11-23 7 13-41 10 8-12 55
8-15 22 12-26 7 192429 9-65 5 8-15 39
8-19 18 188210 5-19 12 10-3 12 8-20 44
168718 2-38 24 5-25 12 11-4 222501 8-7 35
8-8 43 5-27 1 193554 9-67 1 8-11 35
8-11 18 5-57 17 194607 12-3 14 8-29 8
8-15 22 5-61 17 197067 9-15 4 222504 5-9 8
8-19 18 5-69 39 9-19 4 222509 8-8 44
169874 1-40 19 188515 9-27 7 198518 11-16 12 8-12 50
1-47 26 9-29 18 198675 2-37 14 8-15 37
170658 1-61 1 9-31 7 199917 9-67 9 8-20 42
1-63 7 9-33 4 201829 12-17 6 222510 13-15 17
1-63 26 9-35 4 204128 9-47 2 222512 5-9 9
174413 2-37 15 188517 9-27 11 204223 4-11 3 5-13 3
175821 6-4 38 9-29 8 213099 5-15 24 226430 6-5 64
175861 9-15 8 9-31 11 5-21 24 6-7 3
9-19 8 9-33 11 5-27 41 6-9 3
175944 4-123 6 9-35 11 5-53 37 227157 1-45 4
4-123 8 190380 4-52 5 5-59 37 1-45 13
4-155 9 190383 4-123 6 5-69 7 1-47 4
4-159 11 4-123 8 213619 9-3 28 1-47 13
178119 11-4 30 4-143 4 215211 12-9 9 230315 7-10 46
178794 3-9 20 4-145 4 215301 12-17 4 230421 7-9 6
181045 4-123 1 4-147 1 215425 10-11 5 230882 9-15 3
4-123 9 4-147 2 12-17 4 9-19 3
181046 4-123 4 190580 11-20 15 216590 5-15 37 233683 5-16 47
4-123 7 11-24 15 5-21 37 5-22 47
181089 4-105 17 12-26 15 5-53 40 5-54 47
4-111 16 190887 11-16 2 220428 3-39 2 5-60 47
181266 11-33 11-20 16 221353 1-25 15 8-7 23
12-37 11-24 16 1-33 8-12 51
181298 10-23 11 12-26 16 1-39 11 8-15 38
10-25 11 191072 12-3 14 221530 1-33 8-20 46
11-33 191081 12-3 14 221533 1-33 14 233693 5-15 5
12-37 191941 1-23 6 221536 1-25 13 5-21 5
181482 6-24 2 1-27 11 1-39 13 5-31 16
182005 13-15 13 1-29 15 221542 1-40 28 5-53 6
182118 3-23 18 1-35 8 221544 2-33 13 5-59 6
3-25 22 1-37 8 221628 11-11 5 5-65 31
3-29 34 192424 10-21 15 221717 12-3 13 5-73 9
3-33 13 11-31 25 13-21 2 5-74 2
182342 12-3 14 12-34 25 221771 1-53 3 234038 6-3 19
184451 3-23 21 13-21 14 222036 2-21 28 6-4 41
3-25 14 13-29 16 222443 5-31 15 235691 5-16 48
3-29 4 13-35 16 5-65 30 5-22 48
3-33 17 13-41 11 9-72 6 5-27 18
185856 7-9 30 192425 10-21 14 222444 5-16 47 5-31 24
185857 7-9 30 11-31 24 5-31 28 5-53 8
15-4 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

5-59 8 5-3 266733 7-9 13 5-69 25

5-65 11 11-16 6 268573 2-57 3 292516 5-15 29
5-69 15 264148 4-7 19 268619 7-15 5 5-21 29
5-69 21 4-11 17 270077 10-11 6 5-31 7
239503 8-7 26 4-55 5 12-17 6 5-53 30
8-11 28 264159 9-3 20 272133 1-25 22 5-59 30
8-15 25 265731 7-13 6 273338 13-17 7 5-65 33
8-19 27 8-7 33 275493 4-93 10 292517 2-27 15
240072 2-27 6 8-11 33 4-127 6 292522 5-69 16
2-29 6 8-27 5 4-139 5 292526 5-19 27
241079 9-65 8 8-29 11 4-139 17 5-25 27
243975 10-7 2 10-17 5 4-159 9 5-57 29
244167 11-4 31 10-23 1 275495 4-93 6 5-62 29
244540 8-12 44 10-23 2 4-159 10 6-3 22
8-19 35 10-25 1 275496 4-127 11 292528 6-3 21
246108 2-9 34 10-25 2 4-139 10 10-21 17
2-13 32 11-29 50 275497 4-127 17 11-31 7
2-17 33 11-33 1 4-140 21 12-33 7
2-21 11-33 2 280154 9-3 18 13-21 8
2-34 50 11-33 8 9-3 25 13-29 18
2-37 6 12-30 38 10-8 22 13-35 18
3-14 32 12-37 1 11-4 21 13-41 17
3-19 12-37 9 280878 12-3 14 292531 5-3 4
3-29 43 12-37 14 287851 4-21 2 292559 2-25 7
252729 5-7 1 13-15 14 4-61 14 292591 10-3 9
5-7 8 13-15 15 6-4 31 11-4 42
5-7 9 13-15 18 292500 1-25 20 12-3 17
5-9 1 13-21 19 1-45 22 292629 1-19 7
5-9 8 13-21 22 5-15 18 292631 1-19 7
5-9 9 13-29 25 5-19 13 292653 13-13 5
5-11 3 13-29 26 5-21 18 292656 1-53 5
5-13 3 13-29 27 5-25 13 292668 4-7 20
5-16 44 13-29 28 5-27 37 4-12
5-22 44 13-35 9 5-31 19 292679 13-9 4
5-53 18 13-35 26 5-53 22 292680 5-15 17
5-60 43 13-35 27 5-57 15 5-19 14
5-66 40 13-41 23 5-59 22 5-21 17
10-8 24 13-41 26 5-61 15 5-25 14
11-3 12 13-41 27 5-69 2 5-27 35
12-14 20 265787 7-13 6 292505 10-31 25 5-31 18
13-19 5 8-7 30 11-39 20 5-53 23
254007 4-52 6 8-7 32 12-45 8 5-57 14
257291 1-5 8-11 30 292508 6-3 27 5-59 23
257913 11-20 5 8-11 32 292509 5-15 2 5-61 14
12-26 5 8-27 1 5-21 2 5-65 13
262798 4-52 6 8-27 3 5-31 20 5-69 3
263794 2-57 11 8-27 14 5-53 1 6-3 4
263795 2-57 10 8-29 3 5-59 1 8-3 4
263827 2-54 8-29 9 5-69 23 8-5 4
263828 2-53 13 8-29 15 292515 2-27 2 292681 4-7 17
263842 2-43 10 266519 9-53 3 2-29 2 4-12
264134 3-29 29 266728 7-9 26 5-31 27 4-21 3
©2011 HYSTER COMPANY See Service Manual 15-5
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

5-19 21 296022 5-19 22 300937 7-9 37 5-60 48

5-25 21 5-25 22 302023 2-9 27 5-69 4
5-27 12 5-27 33 2-13 26 304523 10-7 5
5-57 24 5-57 25 2-17 25 11-3 7
5-62 24 5-62 25 302024 2-17 25 12-13 4
5-65 6 5-65 24 2-21 24 304527 11-7 14
6-3 26 296032 1-3 23 302363 3-29 6 11-11 19
6-3 26 1-5 27 3-33 25 12-21 22
6-5 68 296149 1-29 13 302381 1-3 10 306113 9-15 12
292682 2-27 14 1-35 12 302385 6-4 41 9-19 12
2-29 14 296152 3-13 15 6-4 56 307284 6-21 3
2-33 10 296156 3-25 9 6-5 62 309109 9-15 16
5-15 28 3-33 7 302398 4-22 7 9-17 11
5-21 28 296165 1-45 9 8-7 1 9-19 17
5-31 3 1-47 9 8-11 1 9-21 12
5-53 27 296357 1-25 18 8-15 1 310549 11-8 24
5-59 27 1-33 17 8-19 1 12-21 12
5-65 34 1-40 23 302399 2-9 7 313828 1-25 11
5-69 17 296360 1-45 6 2-13 7 1-33 20
292683 1-53 4 1-45 21 2-17 7 1-40 25
2-3 13 1-47 6 2-21 32 1-45 7
5-3 5 1-47 20 11-39 26 1-45 20
5-19 26 296378 3-37 12 302400 1-23 6 1-47 7
5-25 26 296380 4-5 26 1-27 11 1-47 21
5-57 30 4-7 30 1-29 15 316826 1-45 17
5-62 30 4-12 37 2-34 38 1-47 15
6-3 20 296418 2-33 17 302428 9-15 9 316828 7-9 37
10-21 18 296420 5-4 2 9-19 9 316834 9-15 3
11-31 6 296423 1-53 3 302437 3-37 8 9-19 3
12-33 6 296426 6-3 18 302443 3-37 8 317292 11-31 17
13-21 7 6-4 58 302449 6-3 12 12-33 17
13-29 19 7-9 36 302468 3-33 25 13-29 22
13-35 19 296430 10-3 10 302472 11-7 15 13-35 22
13-41 18 11-4 41 11-11 20 13-41 14
292685 5-3 7 12-3 16 11-28 15 318067 9-67 11
292691 1-19 6 296434 6-5 65 12-21 17 319322 11-31 9
293625 2-33 18 6-7 2 12-30 18 12-33 9
293628 7-9 25 6-9 2 302491 1-19 10 13-29 20
293646 6-4 49 296507 13-9 3 302493 11-11 16 13-35 20
293648 7-9 35 297531 11-20 6 303100 5-15 42 13-41 21
293686 7-9 23 11-23 6 5-21 42 319323 11-31 8
7-9 35 12-26 6 5-27 20 12-33 8
293692 6-3 17 297532 10-11 10 5-54 44 13-29 21
293695 6-5 63 10-13 5 5-60 44 13-35 21
293697 5-3 8 12-18 9 5-65 23 13-41 20
293699 2-31 3 297538 11-23 5 303150 2-27 1 320154 2-9 28
293741 5-74 8 297640 11-8 29 2-29 1 2-13 27
293742 5-60 53 11-12 29 2-31 8 2-17 26
5-69 26 12-22 27 5-16 45 2-17 26
5-73 5 297649 11-7 11 5-22 45 2-21 23
295649 11-16 3 11-11 11 5-31 25 320155 13-9 5
296016 9-3 9 12-22 25 5-54 48 320156 9-15 4
15-6 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

9-19 4 12-29 6 2-13 29 375575 2-43 24

320157 2-34 37 332061 10-7 6 2-17 27 375587 2-53 26
4-61 14 11-3 5 2-21 14 375601 2-43 20
5-15 3 12-13 7 351531 10-13 11 375602 2-43 25
5-21 3 334155 9-67 5 12-18 9 376026 6-5
5-31 21 334560 5-15 30 351532 10-13 9 6-7 14
5-53 2 5-21 30 12-18 12 6-9 11
5-59 2 5-27 32 352205 7-10 49 377211 3-13 21
5-69 20 5-53 31 353000 3-9 7 378044 11-29 41
6-5 67 5-59 31 356916 10-7 2 379405 10-8 26
12-30 29 5-69 5 12-3 14 12-13 14
320160 1-15 4 335988 1-23 357626 11-16 14 13-15 10
1-45 18 335991 1-23 358286 10-17 18 379407 2-49 7
1-47 16 336550 2-9 30 11-28 29 3-3 7
320161 5-19 25 2-13 29 12-30 33 3-5 7
5-25 25 2-17 27 358287 10-17 15 386015 9-27 14
5-57 31 2-21 17 11-28 30 9-29 12
5-62 31 337180 12-22 27 12-30 34 9-31 14
7-9 36 337189 12-22 27 358289 10-17 20 386885 12-22 27
9-15 13 338647 10-7 2 11-28 33 12-22 27
9-19 14 339735 2-9 30 12-30 37 388302 2-43 9
320165 5-3 7 2-13 29 360387 2-25 9 2-43 19
320289 9-27 10 2-17 27 5-4 4 388306 2-57 7
9-29 7 339932 10-8 37 362036 3-39 10 388313 2-43 27
9-31 10 10-21 7 364059 11-20 13 389688 1-61 2
9-33 10 11-8 28 11-24 13 392620 2-37 3
9-35 10 11-12 28 12-26 13 615145 11-20 10
320291 9-27 14 11-31 11 364868 1-5 14 11-23 10
9-29 12 12-3 11 365599 10-7 2 12-26 10
9-31 14 12-7 7 366473 3-13 18 636950 11-20 12
320395 11-8 29 12-22 30 367420 1-48 1 11-23 12
11-12 29 12-33 11 367421 1-48 1 12-26 12
12-22 27 13-21 4 367422 1-48 1 637161 11-20 9
320714 11-8 29 13-29 7 367423 1-48 1 11-23 9
11-12 29 13-35 7 367424 1-48 1 12-26 9
12-22 27 13-41 2 369804 2-9 16 637162 11-20 13
323488 13-15 4 340204 2-9 24 2-13 16 11-23 13
325699 3-39 13 2-17 19 2-17 15 12-26 13
327591 10-8 37 341462 9-27 13 2-21 12 638248 9-67 3
10-21 7 9-29 13 9-3 26 638249 10-11 7
12-3 11 9-31 13 369815 2-9 23 12-18 7
12-7 7 344432 2-9 26 2-13 23 638250 12-18 7
13-21 4 2-17 23 2-17 17 638293 11-20 14
327807 10-13 6 345453 2-9 30 2-21 20 11-24 14
327808 10-13 7 2-13 29 370414 7-15 8 12-26 14
329069 1-3 14 2-17 27 370415 7-15 1 672563 10-17 20
1-3 21 2-21 15 370444 7-16 1 11-28 33
1-5 8 345454 2-9 30 370466 7-9 32 11-29 41
1-5 23 2-13 29 370467 7-9 31 12-30 37
3-37 6 2-17 27 374923 3-7 1 806426 4-7 1
332057 10-17 32 2-21 16 375571 2-27 10 4-8 31
11-28 13 345455 2-9 30 2-29 10 816591 10-17 10
©2011 HYSTER COMPANY See Service Manual 15-7
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

10-23 2 4-117 16 4-118 27 4-101 6

10-25 2 4-118 27 4-121 14 4-101 9
10-27 2 4-118 31 4-122 30 4-103 4
11-29 50 4-121 19 4-123 3 4-103 9
11-33 9 4-122 30 1324309 4-127 10 4-161 3
11-35 2 4-122 35 4-131 8 4-161 5
12-37 2 4-123 3 4-135 13 1327647 2-34 35
12-41 2 4-151 4 4-139 13 1327957 4-105 3
13-29 27 4-151 7 4-139 14 4-108 22
13-35 9 4-151 8 1324310 4-127 10 4-112 30
816593 10-17 10 4-153 4 4-131 8 4-115 2
10-31 17 4-153 7 4-135 13 4-117 14
11-29 50 1323578 4-95 1 4-139 13 4-121 16
11-35 3 4-97 3 4-139 14 1329148 4-98 4
11-37 7 4-98 1 1324360 1-5 19 4-103 6
11-39 11 4-101 7 1324480 1-61 11 1329150 4-63 7
930591 4-155 4 4-103 3 1325120 10-7 8 4-65 35
4-155 8 4-161 6 11-3 8 4-69 6
4-157 4 1323579 4-63 12 12-13 5 4-71 35
4-157 8 4-63 13 1325271 1-63 14 4-75 6
4-159 4 4-63 14 1326653 8-25 8 4-78 37
4-159 7 4-64 15 1327164 4-63 7 4-81 6
980929 9-72 3 4-69 12 4-63 12 4-83 37
1301286 13-8 4 4-69 13 4-63 13 4-88 20
1302024 4-59 3 4-69 14 4-63 14 1329151 4-63 6
13-5 12 4-70 15 4-65 35 4-63 7
1302955 2-9 22 4-75 12 4-69 6 4-65 34
2-13 22 4-75 13 4-69 12 4-65 35
2-17 18 4-75 14 4-69 13 4-69 5
2-21 19 4-76 15 4-69 14 4-69 6
1305165 2-33 12 4-81 12 4-71 35 4-71 34
1307994 4-53 4 4-81 13 4-75 6 4-71 35
1309839 2-43 12 4-81 14 4-75 12 4-75 5
1309993 2-37 9 4-82 15 4-75 13 4-75 6
2-38 20 4-88 25 4-75 14 4-77 36
4-7 10 4-88 26 4-78 37 4-78 37
4-11 15 4-89 27 4-81 6 4-81 5
1310370 11-16 9 4-89 28 4-81 12 4-81 6
1310371 11-16 9 4-95 3 4-81 13 4-83 36
1316487 2-34 41 4-97 6 4-81 14 4-83 37
1316488 2-34 47 4-98 5 4-83 37 4-87 5
1317007 9-67 6 4-101 5 4-87 6 4-87 6
1320000 2-53 27 4-101 9 4-88 20 4-88 19
1323576 4-89 29 4-103 9 4-88 25 4-88 20
4-95 5 4-161 3 4-88 26 4-103 6
4-95 6 1323586 4-105 14 4-89 28 1329152 4-63 6
4-97 8 4-107 7 4-95 2 4-65 34
4-97 9 4-107 10 4-95 3 4-69 5
4-107 10 4-111 9 4-97 4 4-71 34
4-108 25 4-111 13 4-97 6 4-75 5
4-111 13 4-115 12 4-98 2 4-77 36
4-112 33 4-117 13 4-98 5 4-81 5
15-8 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

4-83 36 4-155 8 4-63 4 4-139 9

4-87 5 4-157 4 4-64 19 4-139 15
4-88 19 4-157 8 4-65 27 4-139 19
4-98 4 4-159 4 4-65 29 4-140 23
4-103 6 4-159 7 4-66 39 4-140 25
1329286 6-5 71 1330356 4-63 3 4-66 40 4-140 27
6-7 5 4-65 32 4-69 3 4-140 30
6-9 5 4-71 32 4-69 7 4-143 1
1330281 4-63 6 4-77 34 4-69 8 4-143 8
4-63 13 4-83 34 4-70 19 4-143 9
4-63 14 4-87 3 4-71 27 4-145 1
4-64 15 4-107 12 4-71 29 4-145 10
4-65 34 4-111 15 4-75 3 4-145 11
4-69 5 4-118 30 4-75 7 4-147 3
4-69 13 4-122 32 4-75 8 4-147 4
4-70 14 4-155 4 4-76 20 4-147 5
4-70 15 4-155 8 4-77 29 4-151 5
4-71 34 4-157 4 4-77 31 4-153 5
4-75 5 4-157 8 4-81 3 4-155 1
4-75 13 4-159 4 4-81 7 4-157 1
4-76 14 4-159 7 4-81 8 4-159 1
4-76 15 1330413 4-108 20 4-82 20 1330439 4-64 20
4-77 36 4-112 28 4-83 29 4-64 21
4-81 5 4-117 2 4-83 31 4-64 23
4-81 13 4-121 2 4-87 9 4-65 36
4-81 14 1330414 1-21 9 4-87 11 4-66 37
4-82 15 4-52 4 4-87 13 4-70 20
4-83 36 4-93 9 4-88 17 4-70 23
4-87 5 1330416 3-39 4 4-89 35 4-71 36
4-88 19 4-61 6 4-89 36 4-72 37
4-88 25 4-61 17 4-90 46 4-76 22
4-88 27 4-65 28 4-90 48 4-76 25
4-89 28 4-71 28 4-93 11 4-78 38
1330355 4-63 3 4-77 30 4-127 1 4-78 39
4-65 32 4-83 30 4-127 13 4-82 23
4-71 32 4-90 47 4-127 14 4-82 25
4-77 34 1330433 4-61 18 4-127 19 4-84 38
4-83 34 1330437 1-21 10 4-128 21 4-84 39
4-87 3 4-52 4 4-128 23 4-87 7
4-107 6 4-61 7 4-131 7 4-87 8
4-107 15 4-65 28 4-131 10 4-89 39
4-108 23 4-71 28 4-131 13 4-90 41
4-111 8 4-77 30 4-131 14 4-143 1
4-111 20 4-83 30 4-132 18 1330450 2-43 6
4-112 31 4-90 47 4-135 3 1330453 2-57 5
4-117 12 4-93 9 4-135 6 1330917 1-63 2
4-117 15 4-128 25 4-135 11 1330919 1-63 1
4-118 33 4-132 17 4-135 12 1330920 1-63 20
4-121 13 4-136 23 4-135 15 1331341 2-43 26
4-121 17 4-140 29 4-136 18 1331990 10-8 36
4-122 36 1330438 4-25 2 4-136 19 12-3 10
4-155 4 4-61 10 4-136 24 1331991 10-8 36
©2011 HYSTER COMPANY See Service Manual 15-9
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

11-8 27 1354165 1-63 15 4-157 7 11-37 3

11-12 27 1354171 1-63 8 4-157 9 11-39 5
12-3 10 1354237 4-107 7 4-159 3 12-37 11
12-22 28 4-108 22 4-159 6 12-43 3
1333001 1-49 1 4-108 25 4-159 8 12-45 11
1333002 1-49 1 4-111 9 1367150 1-43 7 1377954 10-23 10
1333003 1-49 1 4-112 30 1-43 10 10-25 10
1333004 1-49 1 4-112 33 1367369 9-3 5 10-29 3
1333541 2-57 6 4-117 13 1371149 3-9 17 10-31 10
1334423 2-49 5 4-117 14 1371237 2-55 11-33 6
4-56 4 4-118 31 1374107 2-54 41 11-37 4
1335129 1-63 21 4-121 14 1374108 2-53 15 11-39 6
1335137 1-61 8 4-121 16 1374190 1-29 10 12-37 10
1335497 4-56 8 4-122 35 1374288 2-49 6 12-43 4
1335499 2-43 16 1354923 1-53 2 1374289 2-49 11 12-45 10
1337197 4-57 7 1357268 4-7 1 1374290 2-49 3 1378677 9-67 15
1338222 2-27 9 1359458 5-16 52 1374293 2-49 14 1379063 11-16 4
2-29 9 5-22 52 1374297 2-53 2 12-18 11
1338223 2-57 2 5-53 26 1374298 2-53 8 1380092 7-15 3
1339963 2-53 20 5-59 26 1374299 2-53 7 1380849 5-54 52
1340470 3-39 12 1360178 2-54 33 1374301 2-53 6 5-60 55
1345190 10-17 36 1360179 2-43 4 1374313 2-43 15 1380897 9-67 12
1345939 1-63 13 1360182 2-43 5 2-53 25 1380982 11-20 12
1346752 9-15 23 1360507 9-71 22 1374314 2-53 22 11-23 12
9-17 14 10-17 25 1374315 2-53 19 12-26 12
9-19 24 10-17 27 1374317 2-53 18 1381049 9-67 2
9-21 15 11-28 9 1374319 2-57 1 1381055 11-16 5
1347045 1-3 22 11-29 40 1374320 2-57 4 1381056 11-16 5
1-5 34 12-29 11 1374323 2-55 1381061 10-11 9
1-10 42 1360508 9-71 2 1374326 2-53 21 12-18 10
1-14 42 1360529 10-8 32 1374823 7-9 31 1381062 10-13 10
1350215 1-9 18 11-28 18 1375391 8-8 42 12-18 10
1-13 18 12-13 17 8-12 42 1381074 11-20 14
13-11 3 1361302 11-20 4 8-15 34 11-24 14
1351139 4-107 12 11-23 4 8-19 33 12-26 14
4-111 15 12-26 4 8-25 13 1381084 11-16 10
4-118 30 1362049 1-27 1375487 6-3 6 1381085 9-67 4
4-122 32 1-29 1375498 6-4 55 1381086 11-16 10
1351682 4-135 7 1-33 1375676 1-63 12 1382111 1-27 3
1351689 8-8 41 1362058 1-27 2 1377103 2-54 39 1-29 1
8-12 41 1-29 9 1377104 2-54 41 1-33 1
8-15 33 1-33 10 1377107 2-53 23 1382112 1-27 6
8-19 32 1363886 4-65 27 1377110 2-47 3 1-29 4
8-25 14 4-71 27 1377750 2-33 14 1-33 3
1352140 2-9 32 4-77 29 1377792 2-49 15 1382113 1-27 3
2-13 33 4-83 29 1377793 2-49 16 1-29 1
2-17 30 4-90 46 1377794 2-49 17 1-33 1
2-21 2 4-124 10 1377953 10-23 9 1382114 1-27 6
1352603 4-128 25 4-155 3 10-25 9 1-29 4
4-132 17 4-155 7 10-29 4 1-33 3
4-136 23 4-155 10 10-31 11 1382130 13-5 1
4-140 29 4-157 3 11-33 7 1383056 9-67 8
15-10 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1383057 9-67 8 1387743 11-7 20 1398099 3-23 30 11-31 14

1383066 10-11 8 11-11 18 3-25 2 12-33 14
12-17 5 12-21 19 3-29 22 13-21 17
1383067 10-13 8 1387744 10-5 5 3-33 2 13-29 5
1383068 12-17 5 1387745 10-5 5 1399079 10-7 3 13-35 10
1383070 11-20 8 1387993 10-21 11 1399080 12-13 18 13-41 5
11-23 8 11-31 4 12-13 18 1399243 12-30 25
12-26 8 12-33 4 1399084 10-7 3 1399323 8-27 24
1383257 2-34 42 13-21 12 12-13 18 11-28 22
2-53 11 13-29 12 1399085 11-39 15 1399916 1-48 1
1383263 2-53 17 13-35 12 1399088 12-13 18 1399917 1-48 1
1383331 4-5 22 13-41 9 12-13 18 1399919 1-49 1
1383775 7-10 42 1388019 10-7 19 1399091 10-7 3 1399920 1-49 1
1383777 7-9 40 11-3 20 1399093 10-7 4 1399921 1-49 1
1383904 2-49 10 12-14 22 1399096 10-7 3 1399922 1-49 1
1385102 1-61 3 1388829 7-9 4 12-13 18 1400501 11-16 8
1386176 2-53 28 1389050 2-49 19 12-13 18 1400551 11-16 8
2-57 1389051 2-47 2 12-13 19 1400801 11-16 8
1386177 2-57 8 2-49 20 12-13 19 1400807 11-16 8
1386179 2-54 38 1389092 2-54 40 1399098 10-7 4 1400851 11-16 8
1386183 2-54 32 1389093 2-49 12 1399100 12-13 19 1400857 11-16 8
1386184 2-54 31 1389100 2-53 12 1399103 10-7 3 1401630 10-21 1
1386187 2-50 1389102 2-49 2 1399104 12-13 19 1401632 10-21 1
1386189 2-49 21 1389672 12-9 12 12-13 19 1401634 10-21 1
1386190 2-49 22 1389673 12-9 12 1399105 10-7 4 1401635 12-33 1
1386194 2-47 4 1389779 12-9 12 1399110 10-7 4 1401636 12-33 1
1386195 2-47 5 1389780 12-9 12 1399112 12-13 19 1401637 12-33 1
1386197 2-47 7 1389825 11-8 22 12-13 19 1401638 12-33 1
1386198 2-47 8 11-11 15 1399116 13-15 12 1401639 12-33 1
1387170 1-5 9 12-21 13 1399117 10-7 4 1401640 11-31 1
1387281 11-11 17 1389828 12-30 23 1399203 10-3 3 1401642 11-31 1
1387285 10-21 6 1389846 10-7 17 10-5 2 1401644 11-31 1
12-7 6 12-9 11 11-4 35 1401648 12-33 1
13-21 5 1389854 12-30 28 11-7 10 1401660 10-21
1387286 10-21 6 1389932 12-10 18 11-11 8 1401662 10-21
12-7 6 1389959 10-5 8 12-3 3 1401664 10-21
13-21 5 12-9 14 12-9 3 1401665 12-33
1387327 12-30 13 1390759 2-43 2 1399204 10-3 3 1401666 12-33
1387330 1-53 2 1390760 2-43 2 10-5 2 1401667 12-33
1387339 1-53 1 1390761 2-43 3 11-4 35 1401668 12-33
1387340 1-53 1 1390765 2-43 3 11-7 10 1401669 12-33
1387341 1-53 1 1390770 2-43 7 11-11 8 1401670 11-31
1387342 1-53 1 1393127 2-47 6 12-3 3 1401672 11-31
1387347 1-53 1 1393879 1-14 49 12-9 3 1401674 11-31
1387348 1-53 1 1394001 4-53 3 1399205 10-3 3 1401675 13-21
1387479 12-21 7 1395480 10-7 2 10-5 2 1401676 13-21
1387519 11-7 19 1396346 8-27 26 11-4 35 1401678 13-21
11-11 21 1397682 11-28 23 11-7 10 1401679 13-35
12-21 16 1397716 4-7 16 11-11 8 1401680 13-35
1387523 12-29 5 4-11 18 12-3 3 1401682 13-41
1387553 12-21 2 1398062 4-19 8 12-9 3 1401683 13-29
1387740 12-21 19 8-25 10 1399224 10-21 5 1401684 13-29
©2011 HYSTER COMPANY See Service Manual 15-11
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1401686 13-41 4-145 8 4-98 1 1-27 9

1401688 12-33 4-145 9 4-98 4 1-29 7
1401695 13-21 1 4-147 1 4-101 7 1460322 2-53 14
13-23 1402815 4-63 10 4-103 3 1460330 2-43 21
1401696 13-21 1 4-69 10 4-103 6 1460331 2-43 23
13-25 4-75 10 4-161 6 1460384 2-47 9
1401698 13-21 1 4-81 10 1402912 4-95 3 1460386 2-43 8
13-27 4-88 24 4-97 6 1460477 1-3 24
1401699 13-35 1 4-143 2 4-98 5 1-5 28
13-37 4-145 2 4-101 9 2-4 26
1401700 13-35 2 1402816 4-7 24 4-103 9 2-27 4
13-39 4-11 28 4-161 3 2-29 4
1401702 13-41 1 4-123 5 1402926 4-95 7 2-33 8
13-45 4-127 15 4-97 1 13-3 3
1401703 13-29 1 4-131 6 4-98 6 1460738 2-43 11
13-31 4-135 10 4-101 1 1460757 2-53 30
1401704 13-29 1 4-139 16 4-161 1 1460758 2-53 30
13-33 4-151 2 1402927 4-95 7 1461743 4-97 7
1401706 13-41 1 4-153 2 4-97 1 4-101 8
13-43 1402868 4-89 29 4-98 6 4-103 8
1401800 10-5 1 4-151 4 4-101 1 4-161 3
10-5 1 4-153 4 4-103 1 1461744 4-95 3
1401806 10-5 1 1402877 4-107 6 4-161 1 4-97 6
10-5 1 4-107 12 1402929 4-95 7 4-98 5
1401812 10-5 1 4-108 23 4-97 1 4-101 9
1402189 2-3 10 4-111 8 4-99 6 4-103 9
2-4 28 4-111 15 4-101 1 4-161 3
1402414 3-30 47 4-112 31 4-103 1 1463138 4-93 7
3-33 22 4-117 12 1450503 7-2 2 4-151 1
1402613 4-117 16 4-118 30 1450555 2-43 22 4-151 11
4-121 19 4-118 33 1450941 2-57 9 4-153 1
1402629 4-7 23 4-121 13 1451319 2-43 17 4-153 10
4-11 24 4-122 32 1451321 2-53 24 13-5 4
1402809 4-107 14 4-122 36 1453247 2-33 15 13-6 2
4-111 19 1402883 4-5 20 1454827 4-105 15 1463139 4-63 9
4-115 4 1402888 4-63 6 4-107 9 4-64 17
4-118 29 4-64 14 4-115 13 4-64 18
4-122 31 4-65 34 4-118 26 4-64 19
1402813 4-151 10 4-69 5 1454829 4-105 15 4-64 24
4-153 9 4-70 14 4-107 9 4-64 25
1402814 4-108 24 4-71 34 4-115 13 4-65 26
4-112 32 4-75 5 4-118 24 4-65 30
4-118 32 4-76 14 1454862 4-105 15 4-65 31
4-122 34 4-77 36 4-107 9 4-69 9
4-143 3 4-81 5 4-115 13 4-70 17
4-143 5 4-82 14 4-118 25 4-70 18
4-143 6 4-83 36 1454955 2-53 9 4-70 19
4-143 7 4-87 5 1454957 2-53 10 4-70 24
4-145 3 4-88 19 1456112 2-27 8 4-70 25
4-145 5 4-89 28 2-29 8 4-71 26
4-145 6 4-95 1 1458264 1-49 1 4-71 30
4-145 7 4-97 3 1459173 1-23 5 4-71 31
15-12 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

4-75 9 4-131 7 1465545 1-50 1 13-31 7

4-76 17 4-135 6 1465546 1-50 1 13-33 7
4-76 18 4-135 11 1465547 1-50 1 13-37 6
4-76 21 4-135 12 1465548 1-50 1 13-39 7
4-77 26 4-139 15 1465585 10-8 31 1467153 13-23 9
4-77 27 4-139 19 12-13 16 13-25 9
4-77 28 1463910 13-13 2 1465897 13-19 1 13-31 10
4-77 32 1464863 1-53 1 1466633 12-10 13-33 10
4-77 33 1465028 10-21 16 1467145 13-23 11 13-37 9
4-81 9 11-31 5 13-25 11 13-39 10
4-82 17 12-33 5 13-27 4 1467154 13-23 14
4-82 18 13-21 11 13-31 3 13-25 14
4-82 21 13-29 17 13-33 3 13-31 14
4-82 26 13-35 17 13-37 11 13-33 14
4-83 27 13-41 13 13-39 4 13-37 14
4-83 28 1465072 10-3 4 13-43 5 13-39 14
4-83 32 10-5 3 13-45 4 1467200 13-27 2
4-83 33 10-21 4 1467146 13-23 12 13-43 3
4-87 1 11-4 33 13-25 12 13-45 2
4-87 2 11-7 8 13-27 13 1467201 13-27 12
4-88 21 11-11 6 13-31 12 13-43 17
4-88 23 11-31 13 13-33 12 13-45 12
4-89 31 12-3 5 13-37 12 1467203 13-27 9
4-89 32 12-7 5 13-39 12 13-43 9
4-89 33 12-9 6 13-43 14 13-45 9
4-90 42 12-33 13 13-45 13 1467204 13-27 8
4-90 43 13-21 15 1467147 13-23 2 13-43 8
4-90 44 13-29 4 13-25 2 13-45 8
4-90 45 13-35 30 13-27 3 1467205 13-27 11
4-93 1 13-41 6 13-31 2 13-43 11
4-93 2 1465177 10-21 13 13-33 2 13-45 11
4-127 2 11-31 3 13-37 2 1467206 13-27 16
4-127 5 12-33 3 13-39 3 13-43 19
4-128 20 13-21 6 13-43 2 13-45 16
4-128 24 13-29 14 13-45 3 1467523 1-35
4-131 1 13-35 14 1467148 13-23 3 1-37
4-131 12 13-41 16 13-25 3 1467524 1-35
4-131 16 1465468 4-95 2 13-27 5 1-37
4-135 1 4-97 4 13-31 4 1467525 1-35
4-135 17 4-98 2 13-33 4 1-37
4-136 22 4-101 6 13-37 3 1467526 1-35
4-139 1 4-103 4 13-39 2 1-37
4-139 4 4-161 5 13-43 4 1467527 1-35
4-139 6 1465469 4-95 1 13-45 5 1-37
4-140 24 4-97 3 1467150 13-23 7 1467529 1-35
4-140 28 4-98 1 13-25 7 1-37
4-155 6 4-101 7 13-31 8 1467632 13-23 8
4-157 6 4-103 3 13-33 8 13-25 8
4-159 5 4-161 6 13-37 7 13-31 9
1463140 4-148 3 1465489 9-71 21 13-39 8 13-33 9
1463194 4-127 13 10-17 26 1467151 13-23 6 13-37 8
4-127 14 12-29 12 13-25 6 13-39 9
©2011 HYSTER COMPANY See Service Manual 15-13
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1467633 13-23 15 13-21 22 4-117 15 4-7 5

13-25 15 1473888 9-3 18 4-121 17 4-11 9
13-27 17 1473897 8-27 5 4-155 4 5-7 3
13-31 15 8-29 11 4-155 8 5-9 3
13-33 15 9-71 7 4-157 4 5-11 5
13-37 15 9-71 8 4-157 8 5-13 5
13-39 15 13-21 19 4-159 4 7-13 8
13-43 20 13-29 26 4-159 7 9-69 7
13-45 17 13-35 26 1476109 4-65 32 9-71 15
1467634 13-27 15 1473898 9-3 25 4-71 32 1481225 1-53 1
13-43 10 9-73 1 4-77 34 1482663 4-63 3
13-45 15 1474354 10-3 11 4-83 34 4-107 6
1469405 2-3 12 11-4 40 4-87 3 4-108 23
1469606 4-123 2 12-3 15 4-107 12 4-111 8
1470152 1-35 1 1474387 12-14 24 4-107 15 4-112 31
1-37 1 1474399 10-7 12 4-108 25 4-117 12
1470153 1-35 1 11-3 13 4-111 15 4-118 33
1-37 1 1474496 12-13 11 4-111 20 4-121 13
1470155 1-35 1474497 12-13 11 4-112 33 4-122 36
1-37 1474893 4-7 1 4-117 15 1482666 4-97 5
1-40 1476064 4-65 32 4-118 30 4-101 4
1470156 1-35 2 4-71 32 4-118 31 4-103 7
1-37 4 4-77 34 4-121 17 1482667 4-63 3
1470157 1-35 2 4-83 34 4-122 32 4-105 4
1-37 4 4-87 3 4-122 35 4-107 6
1470160 1-37 4-105 11 1476421 2-9 6 4-108 23
1470161 1-35 6 4-115 9 2-13 6 4-111 8
1-37 5 1476067 4-105 18 2-17 6 4-112 31
1470163 1-35 5 4-107 15 2-21 29 4-115 5
1-37 6 4-111 20 2-21 33 4-117 12
1471555 2-47 2 4-115 6 1477166 1-48 4 4-118 33
1471556 2-53 3 4-117 15 1-50 4 4-121 13
1471557 2-47 1 4-121 17 1477237 1-48 7 4-122 36
2-49 24 1476071 4-105 16 1-50 7 1482668 4-155 4
1471558 2-53 29 4-107 12 1477559 10-7 16 4-155 8
1471559 2-49 18 4-111 15 11-3 16 4-157 4
1471560 2-49 25 4-115 8 1477570 10-17 33 4-157 8
1473887 9-69 11 4-118 30 1477578 10-17 29 4-159 4
9-71 14 4-122 32 1480187 4-64 23 4-159 7
10-17 19 1476077 4-95 5 4-70 23 1482701 2-47 4
10-23 12 4-97 8 4-76 25 1482905 1-43 4
10-25 12 1476108 4-63 3 4-82 25 1482906 1-43 6
10-29 2 4-65 32 4-90 41 1482950 1-25 9
10-31 9 4-71 32 1480237 1-9 17 1483023 1-27 7
11-29 46 4-77 34 1-13 17 1-29 5
11-33 2 4-83 34 1-13 17 1483828 1-35
11-37 2 4-87 3 2-9 9 1484377 4-25 2
11-39 4 4-97 5 2-13 9 4-64 17
12-30 38 4-101 4 2-17 21 4-64 19
12-37 14 4-103 7 2-17 21 4-64 24
12-43 2 4-107 15 3-9 3 4-64 25
12-45 9 4-111 20 4-5 11 4-65 26
15-14 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

4-65 29 4-136 23 13-29 28 4-131 10

4-65 30 4-140 24 13-35 23 4-132 18
4-65 31 4-140 28 1487058 8-8 38 4-135 3
4-70 17 4-140 29 8-12 38 4-135 15
4-70 19 4-147 4 1487061 8-7 32 4-136 24
4-70 24 4-151 1 8-11 32 4-139 9
4-70 25 4-151 11 8-27 3 4-140 23
4-71 26 4-153 1 8-29 3 4-140 30
4-71 29 4-155 1 9-69 4 1489657 4-61 9
4-71 30 4-157 1 1487063 9-69 5 4-66 40
4-71 31 4-159 1 1487066 8-7 33 4-69 8
4-76 17 1484397 4-127 13 8-11 33 4-75 8
4-76 20 4-127 14 1487067 5-7 9 4-81 8
4-77 26 4-131 7 5-9 9 4-87 13
4-77 27 4-135 6 5-11 3 4-124 10
4-77 28 4-135 11 5-13 3 4-127 1
4-77 31 4-135 12 5-16 44 4-127 19
4-77 32 4-139 15 5-28 48 4-131 10
4-77 33 4-139 19 5-53 18 4-132 18
4-82 17 1484557 4-127 5 5-66 40 4-135 3
4-82 20 4-139 4 1487068 10-8 24 4-135 15
4-82 26 4-139 6 11-3 12 4-136 24
4-83 27 4-155 6 12-13 20 4-139 9
4-83 28 4-157 6 1487086 13-15 18 4-140 23
4-83 31 4-159 5 1487095 10-31 1 4-140 30
4-83 32 1484558 4-127 5 11-39 1 1490242 4-63 4
4-83 33 4-139 4 12-45 1 4-66 39
4-87 1 4-139 6 13-15 14 4-69 3
4-87 2 4-155 6 1487096 10-7 9 4-69 7
4-88 21 4-157 6 11-4 26 4-75 3
4-88 22 4-159 5 12-14 27 4-75 7
4-88 23 1484709 4-59 16 13-19 5 4-81 3
4-89 36 4-155 2 1488404 13-17 5 4-81 7
4-90 42 4-157 2 1488464 9-69 3 4-87 9
4-90 43 4-157 5 1489643 2-47 10 4-87 11
4-90 44 4-159 2 1489655 3-39 5 4-88 17
4-90 45 1486555 5-22 44 4-61 5 4-89 35
4-90 48 5-60 42 4-61 16 4-93 11
4-93 1 1486737 8-27 21 4-65 28 4-128 23
4-93 2 8-29 18 4-71 28 4-131 14
4-93 3 10-32 27 4-77 30 4-136 19
4-127 2 11-39 23 4-83 30 4-140 27
4-128 20 12-45 25 4-90 47 4-143 8
4-128 24 1486740 7-13 6 1489656 4-61 8 4-143 9
4-128 25 1486745 7-13 6 4-66 40 4-145 10
4-131 1 1486747 13-15 15 4-69 8 4-145 11
4-131 12 1486749 5-7 8 4-75 8 4-147 3
4-132 16 5-9 8 4-81 8 4-151 5
4-132 17 5-11 4 4-87 13 4-153 5
4-135 1 5-13 4 4-124 10 4-155 3
4-135 17 11-4 24 4-127 1 4-155 7
4-136 22 1486772 9-69 10 4-127 19 4-155 10
©2011 HYSTER COMPANY See Service Manual 15-15
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

4-157 3 4-147 1 2-29 17 1502053 4-61 19

4-157 7 1493465 1-21 8 3-39 15 8-29 4
4-157 9 4-52 4 4-5 5 9-71 11
4-159 3 4-93 9 4-15 5 1502055 4-61 13
4-159 6 1494750 5-15 33 4-17 5 1502059 3-13 27
4-159 8 5-21 33 4-19 4 9-72 5
1490243 4-63 4 5-27 30 4-19 4 11-39 16
4-66 39 5-57 20 4-52 2 13-15
4-69 3 5-62 20 4-61 2 1502061 3-13 26
4-69 7 5-65 21 8-7 6 4-7 27
4-75 3 1494888 1-21 8-11 6 4-11 20
4-75 7 1495279 10-17 32 8-15 6 1502066 9-71 10
4-81 3 11-28 13 8-19 6 9-72 4
4-81 7 12-29 6 8-25 3 11-39 17
4-87 9 1498424 4-97 5 13-11 2 13-15
4-87 11 4-101 4 13-13 8 1502079 3-3 9
4-88 17 4-103 7 1500913 4-25 2 3-5 9
4-89 35 1498483 4-95 3 4-65 27 1502543 2-4 24
4-93 11 4-98 5 4-65 29 4-5 2
4-128 23 1500175 10-17 9 4-71 27 4-7 21
4-131 14 1500744 10-3 2 4-71 29 4-12
4-136 19 11-3 2 4-77 29 9-3 11
4-140 27 11-7 2 4-77 31 9-3 29
4-143 8 11-11 2 4-83 29 9-7 5
4-143 9 11-31 2 4-83 31 13-7 4
4-145 10 12-3 2 4-90 46 13-8 2
4-145 11 12-7 2 4-90 48 13-9 7
4-147 3 12-9 2 4-143 1 1502625 4-76 20
4-151 5 12-33 2 4-145 1 4-82 20
4-153 5 1500784 1-48 5 4-147 4 4-89 36
4-155 3 1-50 5 4-147 5 1502626 4-76 20
4-155 7 1500786 1-49 4 4-155 1 4-82 20
4-155 10 1-50 5 4-157 1 4-89 36
4-157 3 1500884 2-43 18 4-159 1 1502809 9-71 1
4-157 7 1500899 4-64 16 1500925 4-128 25 9-71 5
4-157 9 4-70 16 4-132 17 9-71 20
4-159 3 4-76 16 4-136 23 10-17 24
4-159 6 4-82 16 4-140 29 11-28 21
4-159 8 4-89 30 1500970 9-8 4 11-28 39
1490398 1-63 10 4-127 16 1501259 1-63 6 12-30 24
1493428 4-65 29 4-131 11 1501276 5-3 6 12-30 43
4-71 29 4-135 16 1501811 3-9 14 1502810 11-3 11
4-77 31 4-139 20 1501888 3-6 1 1503088 4-97 6
4-83 31 1500900 4-105 5 1501970 3-14 33 4-101 9
4-90 48 4-111 18 1501994 2-41 1 4-103 9
1493435 4-143 6 4-122 33 2-41 1 4-161 3
4-143 7 1500901 1-29 12 1502007 9-3 6 1503334 4-161 1
4-145 7 1-35 9 9-72 2 1504075 2-31 4
4-145 9 4-115 3 1502009 3-3 2 1506738 3-6 4
1493447 4-145 5 4-122 26 3-5 2 1507004 10-3 6
4-145 6 1500912 1-29 14 8-27 16 11-4 43
4-145 8 1-35 10 8-29 26 12-3 18
15-16 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1507047 7-9 2 1510115 2-3 4 4-89 39 5-69 32

1507393 7-9 12 4-15 8 4-108 21 1516199 8-7 30
1507561 7-9 15 4-17 8 4-112 29 8-11 30
1507571 4-95 7 4-19 7 4-117 3 8-27 1
4-97 1 1510116 2-41 8 4-121 3 8-29 9
4-99 6 1510126 6-3 3 4-155 2 9-69 1
4-101 1 8-7 12 4-157 2 1516202 9-69 11
4-103 1 8-11 14 4-159 2 9-71 12
4-161 1 8-15 12 1514598 4-59 16 13-29 25
1507898 7-9 14 8-19 14 4-155 2 13-35 27
1508022 7-9 11 1510649 2-34 46 4-157 2 1516331 6-4 36
1508232 4-101 5 2-50 27 4-159 2 1516332 6-4 36
4-161 4 1511727 3-9 8 1514602 4-64 20 1516333 6-4 36
1509888 4-63 8 1511882 12-7 3 4-65 36 1516334 6-4 36
4-69 2 12-9 4 4-70 20 1516335 6-4 36
4-75 2 1511883 10-21 2 4-71 36 1516536 6-4 32
4-81 2 11-31 16 4-76 19 1516826 5-19 6
4-88 16 12-7 3 4-76 22 5-25 6
4-95 8 12-9 4 4-78 38 5-57 9
4-97 2 12-33 16 4-82 19 5-61 9
4-99 7 13-21 18 4-82 22 5-65 15
4-101 2 13-29 2 4-84 38 1516851 5-15 22
4-103 2 13-35 5 4-87 7 5-21 22
4-105 12 13-41 4 4-89 37 5-53 35
4-111 4 1511884 12-7 3 4-89 38 5-59 35
4-115 10 12-9 4 4-157 5 1517361 4-11 1
4-127 8 1512403 7-2 1 1514603 4-64 20 9-15 15
4-131 3 1512536 1-39 10 4-65 36 9-17 12
4-139 8 1514138 5-73 14 4-70 20 9-19 16
4-151 3 5-74 5 4-71 36 9-21 13
4-153 3 1514267 2-43 19 4-76 19 1517394 9-15 17
4-161 2 1514429 2-33 1 4-76 22 9-17 10
1509889 4-121 15 2-37 1 4-78 38 9-19 15
1509890 4-63 2 2-37 11 4-82 19 9-21 11
4-81 1 2-41 4 4-82 22 1517395 9-15 21
4-88 15 4-11 27 4-84 38 9-17 9
4-93 4 4-31 6 4-87 7 9-19 22
4-135 5 8-7 10 4-89 37 9-21 10
4-151 9 8-11 12 4-89 38 1517405 3-23 33
4-153 8 8-15 10 4-157 5 3-29 11
4-155 5 8-19 12 1514915 2-34 45 1517420 1-9 4
4-157 10 1514597 4-59 16 2-50 26 1-13 4
4-159 12 4-64 20 1514962 2-54 43 1517421 1-9 4
1510113 2-34 51 4-64 21 1514963 2-54 35 1-13 4
3-3 12 4-66 37 1514964 2-54 36 1517656 1-9 33
3-5 12 4-70 20 1514965 2-54 34 1-13 33
4-5 16 4-72 37 1514968 2-43 13 1518330 13-31 13
4-7 12 4-76 22 1515654 5-19 11 1518331 13-23 1
6-7 13 4-78 39 5-25 11 1518333 13-25 1
6-9 10 4-82 23 5-27 4 1518334 13-37 1
8-7 14 4-84 39 5-57 13 1518335 13-39 1
8-11 7 4-87 8 5-61 13 1518337 13-31 1
©2011 HYSTER COMPANY See Service Manual 15-17
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1518338 13-33 1 4-75 12 1-50 4-90 45

1518342 13-27 1 4-75 13 1524267 3-37 1 4-127 20
1518344 13-45 1 4-75 14 1524355 5-41 4-131 12
1518345 13-43 1 4-76 15 5-57 11 4-135 17
1519025 4-105 10 4-81 12 1524356 5-49 4-140 24
4-107 1 4-81 13 5-53 19 1525568 4-64 25
4-111 1 4-81 14 1524371 5-37 4-70 25
4-115 16 4-82 15 5-53 20 4-77 27
4-118 21 4-88 25 1524372 5-15 14 4-83 27
4-122 24 4-88 26 5-33 4-90 44
1519611 4-95 6 4-89 27 1524373 5-15 13 4-127 2
4-97 9 4-89 28 5-45 4-131 1
1520513 4-7 2 1521309 4-52 4 1525354 7-9 34 4-135 1
1520543 4-105 15 1521809 6-4 43 1525442 3-30 46 4-139 1
4-107 9 1521989 4-63 12 3-33 24 1525569 4-65 31
4-115 13 4-63 13 1525451 3-23 29 4-71 31
4-118 24 4-63 14 3-25 11 4-77 33
1520660 5-73 10 4-64 15 3-29 35 4-83 33
5-74 9 4-69 12 3-33 11 4-87 2
1520752 6-4 40 4-69 13 1525459 3-23 14 4-90 43
1520753 6-4 40 4-70 14 3-29 31 1525570 4-64 24
1520754 6-4 40 4-70 15 3-33 33 4-70 24
1520755 6-4 40 4-75 12 1525478 3-29 41 4-76 26
1521005 3-37 2 4-75 13 3-33 20 4-82 26
1521183 4-63 13 4-76 14 1525563 4-65 27 4-90 42
4-69 13 4-76 15 4-71 27 4-128 24
4-75 13 4-81 12 4-77 29 4-131 16
4-81 13 4-81 13 4-83 29 4-136 22
4-88 25 4-82 14 4-90 46 4-140 28
1521184 4-63 14 4-82 15 1525564 4-143 1 1525573 4-135 2
4-69 14 4-88 25 4-143 1 4-139 12
4-75 14 4-88 26 4-145 1 1525577 4-63 11
4-81 14 4-88 27 4-147 5 4-69 11
4-89 28 4-89 28 1525565 4-25 2 4-75 11
1521185 4-64 15 1522424 8-27 11 4-147 4 4-81 11
4-70 15 8-29 20 1525566 4-155 1 4-88 14
4-76 15 1522425 8-27 14 4-157 1 4-127 18
4-82 15 8-29 15 4-159 1 4-131 9
4-88 27 1522426 9-69 12 1525567 4-64 17 4-135 14
1521186 4-63 12 1523732 1-48 3 4-65 26 4-140 22
4-69 12 1-49 3 4-65 30 1525584 4-127 7
4-75 12 1-50 3 4-70 17 4-131 2
4-81 12 1523734 1-48 2 4-71 26 4-135 4
4-88 26 1-49 2 4-71 30 4-139 7
1521188 4-63 12 1-50 2 4-76 17 1525677 5-19 6
4-63 13 1523737 1-48 6 4-77 28 5-25 6
4-63 14 1-50 6 4-77 32 5-31 4
4-64 15 1523739 1-48 4-82 17 5-57 9
4-69 12 1-50 4-83 28 5-61 9
4-69 13 1523741 1-49 5 4-83 32 5-65 15
4-69 14 1-50 6 4-87 1 1525686 5-15 23
4-70 15 1523742 1-49 4-89 31 5-21 23
15-18 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

5-27 39 2-17 22 1-13 12 11-37 1

5-53 36 2-33 19 1527940 1-9 12 11-39 3
5-59 36 3-3 14 1-13 12 12-37 1
5-69 9 3-5 14 1527979 10-31 6 1529046 4-64 17
1527264 4-5 12 3-9 21 11-39 18 4-65 30
1527273 4-95 7 3-37 4 12-45 6 4-65 31
4-98 6 4-5 13 1527983 9-3 13 4-70 17
4-161 1 4-5 25 1528132 4-27 3 4-71 30
1527275 4-107 14 4-7 6 4-29 3 4-71 31
4-115 4 4-11 13 1528133 4-27 4 4-76 17
4-118 29 4-57 9 4-29 4 4-77 32
1527305 4-95 7 4-61 14 1528314 3-9 27 4-77 33
4-97 1 5-7 5 1528315 4-27 2 4-82 17
4-99 6 5-9 5 4-29 2 4-83 32
4-101 1 5-11 2 1528327 9-17 4 4-83 33
4-103 1 5-13 2 1528328 9-15 14 4-87 1
4-161 1 5-54 53 9-21 4 4-87 2
1527395 1-21 5-60 56 1528329 9-19 13 4-89 31
1527813 8-8 38 7-13 3 1528339 9-15 5 4-127 2
8-12 38 8-7 11 9-19 5 4-127 20
8-27 11 8-11 13 1528481 9-4 4-128 24
8-27 21 8-15 11 1528482 2-3 17 4-131 1
8-29 18 8-19 13 2-33 26 4-131 12
8-29 20 8-27 25 4-19 8 4-131 16
13-17 6 9-3 17 1528580 12-30 19 4-135 1
1527876 1-3 6 9-15 2 13-41 27 4-135 17
1-3 18 9-17 2 1528630 4-27 5 4-136 22
1-5 18 9-19 2 4-29 5 4-139 1
2-13 5 9-21 2 1528631 4-27 6 4-140 24
2-17 5 9-71 17 4-29 6 4-140 28
2-21 35 1527880 1-3 12 1528778 8-25 12 1529257 4-11 11
2-34 54 1-5 6 10-23 3 1529366 2-34 33
2-41 4-5 13 10-23 15 3-9 25
3-17 5 5-7 10 1528888 1-21 12 3-13 14
3-19 8 5-9 10 1528893 3-9 15 4-5 21
4-7 22 6-7 8 1528899 3-23 17 4-7 29
4-11 26 6-9 8 3-25 21 4-12 36
8-8 48 8-8 40 3-29 33 4-15 4
8-12 54 8-12 40 3-33 15 4-15 11
8-16 40 8-15 32 1528903 3-23 23 4-17 4
8-20 45 8-19 31 3-25 19 4-17 4
1527877 2-33 2 8-25 11 3-29 39 4-17 11
2-41 5 1527881 1-3 26 3-33 29 4-19 2
4-11 13 1-5 29 1528906 1-3 15 8-7 9
4-11 13 3-9 6 1528930 2-3 6 8-11 11
13-11 4 3-13 19 1528938 2-3 5 8-15 9
1527878 1-3 17 1527883 6-7 10 1529014 13-17 6 8-19 11
9-15 6 1527885 2-33 24 1529016 10-23 1 8-25 6
9-19 6 10-31 21 10-25 1 1529787 2-9 33
1527879 2-9 10 11-39 12 10-31 8 2-13 31
2-13 10 12-45 21 11-33 1 2-17 31
2-17 22 1527939 1-9 12 11-35 1 2-21 4
©2011 HYSTER COMPANY See Service Manual 15-19
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1529874 5-15 8 1530961 4-148 3 4-89 32 3-29 38

5-21 8 4-151 11 4-93 1 3-33 28
5-53 10 4-153 10 1531975 4-15 3 1534674 3-23 34
5-59 10 1530971 3-37 3 4-17 3 3-29 19
1529890 5-25 17 1531001 1-9 5 1532255 4-53 5 1534675 3-23 31
5-27 28 1-13 5 1532404 13-15 7 3-25 6
5-57 19 4-59 10 1532571 4-127 7 3-29 30
5-62 19 13-5 11 4-131 2 3-33 8
1529897 5-53 1531162 4-143 3 4-135 4 1534677 3-23 8
5-57 4-143 5 4-139 7 3-29 23
1530019 1-9 16 4-145 3 1532585 2-3 7 1534679 3-23 32
1-13 16 1531312 3-39 6 1532637 13-27 14 3-29 27
1530037 4-64 24 1531404 2-9 13-43 18 1534828 4-127 12
4-64 25 2-13 13-45 14 4-131 5
4-65 26 2-18 1532644 13-23 13 4-135 9
4-70 24 1531480 2-29 18 13-37 13 4-139 11
4-70 25 1531486 4-155 4 1532645 13-25 13 4-147 6
4-71 26 4-155 8 13-33 13 1534871 8-7 27
4-76 26 4-157 4 13-39 13 8-12 48
4-77 27 4-157 8 1532664 4-128 21 8-15 26
4-77 28 4-159 4 4-131 13 8-19 39
4-82 26 4-159 7 4-136 18 1535166 4-61 1
4-83 27 1531501 4-64 19 4-140 25 1535257 2-9 29
4-83 28 4-70 19 1532778 4-121 8 2-13 28
4-90 43 1531502 4-105 2 4-122 38 2-17 29
4-90 44 4-115 1 1532779 4-112 24 2-17 29
1530135 1-9 9 1531557 1-21 13 4-115 18 2-21 22
1-13 9 4-5 24 4-121 9 1536304 4-7 1
1530243 1-3 27 1531558 1-10 43 1534017 2-34 31 4-11 3
1-5 31 1-14 43 1534282 4-65 33 1536813 1-21 14
1-15 3 1-21 3 4-71 33 1537449 5-33 14
2-9 2 1-45 8 4-77 35 5-35 14
2-13 2 1-47 8 4-83 35 5-37 14
2-17 2 3-6 5 4-87 4 5-39 14
2-21 6 4-12 32 4-127 4 5-41 14
3-3 13 1531563 7-2 3 4-131 15 5-43 14
3-5 13 1531567 8-7 2 4-136 21 5-45 14
3-13 20 8-11 2 4-139 3 5-47 14
4-5 10 8-15 2 1534417 1-3 13 5-49 14
4-7 13 8-19 2 1-5 10 5-51 14
6-7 11 1531973 4-64 18 2-9 5 1537450 5-33 15
8-7 15 4-70 18 2-37 12 5-35 16
8-12 43 4-76 18 2-38 28 5-37 15
8-15 15 4-82 18 4-5 19 5-39 15
8-19 34 4-88 21 4-55 2 5-41 15
1530311 3-37 5 4-89 32 1534649 3-23 1 5-43 15
1530588 6-4 34 4-93 1 3-29 17 5-45 16
1530722 5-60 52 1531974 4-64 18 1534660 1-61 9 5-47 16
5-73 4 4-70 18 1534671 3-23 25 5-49 16
1530960 4-148 3 4-76 18 3-29 37 5-51 16
4-151 11 4-82 18 1534672 3-23 24 1537455 5-37 2
4-153 10 4-88 21 3-25 17 1537459 5-41 21
15-20 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

5-43 20 5-21 16 4-69 9 4-118 24

5-47 19 5-31 17 4-75 9 1543698 4-11 29
1537551 1-29 11 5-53 21 4-76 21 8-7 16
1-35 11 5-59 21 4-81 9 8-12 47
4-59 7 5-69 18 4-82 21 8-15 16
1538488 3-37 1 1541242 11-28 11 4-88 23 8-19 38
1539198 2-33 12-30 17 4-89 33 8-29 5
2-37 1541243 12-30 30 4-93 2 1543842 3-13 25
2-41 1541420 10-3 1 1542094 6-3 8-7 17
2-43 10-3 1 1542095 6-3 8-12 46
2-47 1541426 10-3 1 1542096 6-3 8-15 17
2-49 10-3 1 1542097 6-3 8-19 37
2-53 1541432 10-3 1 1542103 6-3 24 1543900 3-9 5
2-57 1541455 11-3 1 1542105 6-4 37 1544153 1-9 24
1539273 2-34 48 11-3 1 1542124 6-4 50 1-13 24
1539274 2-34 43 1541461 11-3 1 1542125 6-4 50 1544157 4-7 4
1539313 6-24 1 1541486 7-16 2 1542133 6-4 48 7-13 4
1539315 6-24 1 1541490 7-16 2 1542134 6-4 48 9-71 16
1539317 6-24 1 1541525 6-24 2 1542138 6-4 52 1544186 1-9 23
1539319 6-24 1 1541527 6-24 2 1542143 6-3 23 1-13 23
1539584 4-59 5 1541528 6-24 2 1542144 6-3 25 1544188 1-9 29
13-5 8 1541530 6-24 2 1542146 6-3 29 1-13 29
1540388 4-127 3 1541546 7-16 2 1542147 6-4 32 1544212 2-33 7
4-139 2 1541547 7-16 2 1542157 6-4 45 1544216 5-19 4
1540643 1-10 46 1541556 5-19 5 1542160 6-3 5 5-25 4
1-14 46 5-25 5 1542161 6-3 16 5-27 26
3-11 1 5-27 24 1542169 6-3 28 5-57 6
3-17 2 5-57 5 1542170 6-4 51 5-61 6
3-19 3 5-61 5 1542171 6-4 51 5-65 20
1540694 12-3 1 5-65 19 1542436 3-13 23 1544217 5-19 3
12-3 1 1541640 11-20 3 1542439 3-13 22 5-25 3
1540696 12-3 1 11-23 3 4-61 12 5-27 23
1540697 12-3 1 12-26 3 1542440 4-12 30 5-57 2
12-3 1 1541921 5-4 3 1542546 9-15 10 5-61 2
1540701 12-3 1 1541988 4-88 22 9-19 10 5-65 18
12-3 1 4-93 3 1543094 5-33 14 1544218 5-15 34
1540805 4-5 1 4-93 7 5-45 14 5-21 34
1540861 1-9 20 4-107 19 1543096 5-33 14 5-27 25
1-13 20 4-112 27 5-45 14 5-57 7
1540871 1-9 26 4-117 1 1543097 5-33 14 5-61 7
1-13 26 4-121 1 5-45 14 5-66 38
1540944 4-105 1 1541989 4-93 7 1543098 5-33 14 1544255 4-27 7
4-112 25 1541991 4-63 9 5-45 14 4-29 7
4-112 26 4-69 9 1543102 5-33 1544373 1-19 5
4-115 20 4-75 9 5-37 1544374 1-19 5
1541231 5-15 15 4-76 21 5-41 1544375 1-19 5
5-21 15 4-81 9 5-45 1544376 1-19 5
5-31 23 4-82 21 5-49 1544377 1-19 5
5-53 24 4-88 23 1543254 7-9 38 1544378 1-19 5
5-59 24 4-89 33 1543553 4-105 15 1544379 1-19 5
5-69 19 4-93 2 4-107 9 1544566 7-2 5
1541232 5-15 16 1541992 4-63 9 4-115 13 7-5
©2011 HYSTER COMPANY See Service Manual 15-21
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1544759 5-73 13 4-153 6 1550438 10-8 29 1552853 5-19 19

5-74 6 1548519 4-25 3 1550439 11-4 27 5-25 19
1544846 1-3 2 4-127 9 12-13 8 5-28 46
1544936 1-9 37 4-131 4 1550561 5-73 12 1552973 7-9
1-13 37 4-135 8 5-74 3 1553269 2-27 12
1544937 1-9 37 4-139 18 1550566 5-19 1 2-29 12
1-13 37 4-151 6 1550567 5-19 15 1553270 5-15 43
1545202 4-64 22 4-153 6 5-25 15 5-22 43
4-70 22 1548618 1-5 5 5-27 38 5-54 45
4-76 24 1549449 9-3 15 5-57 16 5-60 45
4-82 24 1550157 10-8 30 5-61 16 1553403 5-16 53
4-89 40 12-13 2 5-69 6 5-22 53
1545546 5-59 18 1550158 12-13 2 1550571 5-19 9 5-27 22
5-69 40 1550193 11-7 7 5-25 9 5-31 8
5-73 3 11-11 9 5-53 16 5-54 51
5-74 12 11-20 17 5-59 16 5-60 51
1546283 2-38 27 1550194 11-7 7 1550572 5-19 10 5-65 26
1546285 2-38 26 11-11 9 5-25 10 1553475 5-16 46
1546673 4-151 7 11-20 17 5-27 2 5-22 46
4-153 7 1550195 12-13 2 5-53 17 5-54 46
1546697 4-64 22 12-21 10 5-59 17 5-60 46
4-70 22 12-26 17 5-69 38 1553541 3-9 24
4-76 24 1550196 12-13 2 1550573 5-15 27 1553897 4-22 8
4-82 24 12-21 10 5-21 27 8-7 3
4-90 40 12-26 17 5-57 12 8-11 3
1547447 5-15 7 1550197 10-7 22 5-61 12 8-15 3
5-21 7 11-4 21 1550576 5-15 12 8-19 3
5-28 43 12-14 25 5-21 12 8-25 5
5-53 9 1550198 10-7 22 1550581 5-53 29 1553964 2-47 1
5-59 9 11-4 21 5-59 29 2-49 24
5-69 31 12-14 25 1550582 5-53 28 1554085 5-4 1
1547483 4-105 6 1550199 11-4 31 5-59 28 1554359 4-64 19
4-108 25 1550201 11-7 1 1550586 5-19 17 4-64 20
4-112 33 11-7 1 1550965 8-27 22 4-64 22
4-115 7 11-11 1 1551663 2-9 13 4-65 36
4-118 31 11-11 1 2-13 13 4-70 19
4-122 35 1550207 11-7 1 2-17 11 4-70 20
1547629 4-101 5 11-11 1 1551665 3-9 13 4-70 22
4-161 4 1550239 10-8 27 1551723 3-9 8 4-72 36
1547849 8-7 4 11-4 22 1551839 7-2 3 4-76 19
8-11 4 1550391 11-27 3 1552141 2-37 4 4-76 22
8-15 4 11-27 3 2-49 3 4-76 24
8-19 4 1550397 11-27 3 1552525 5-33 6 4-78 38
8-25 2 1550425 11-28 28 5-45 6 4-82 19
1547971 1-3 9 11-29 43 1552710 1-9 19 4-82 22
1548517 4-25 3 12-30 20 1-13 19 4-82 24
4-127 9 1550433 10-17 11 1552712 1-9 27 4-84 38
4-131 4 1550434 10-17 12 1-13 27 4-87 7
4-135 8 1550435 10-17 13 1552840 2-38 18 4-89 37
4-139 18 1550436 10-8 29 2-38 31 4-89 38
4-147 2 1550437 11-4 25 1552849 5-53 4-90 40
4-151 6 12-13 8 5-57 1554814 2-34 34
15-22 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1554815 4-53 2 1559561 3-11 4 4-19 10 1-29 6

1554902 4-57 10 1559563 3-11 4 4-22 5 1-33 4
1555731 4-35 1 1559567 2-49 13 1562489 7-5 8 1563351 1-23 1
4-35 1 1559570 2-49 12 1562492 7-5 11 1-25 1
4-35 1 1559695 2-49 4 1562493 7-5 13 1563369 1-3 31
4-35 1 4-56 1562496 7-5 16 1-5 22
1556475 8-7 25 1559922 4-56 3 1562501 7-5 21 1-5 25
8-11 10 1559923 4-56 5 1562505 7-5 25 1563497 1-3 32
8-15 24 1559924 4-56 6 1562509 7-5 1 1-5 21
8-19 10 1559925 4-56 7 1562648 5-7 2 1-5 24
1556794 6-4 44 1559928 4-5 7 5-9 2 1564035 2-33 6
1556795 6-3 10 1559973 9-23 2 5-11 6 1564036 2-38 23
1556799 6-21 7 9-29 2 1562649 4-108 24 1564044 4-7 31
1556800 6-21 1 1560193 2-34 52 4-112 32 1564061 3-13 5
1556897 11-29 44 1560200 2-33 28 4-118 32 1564392 3-9 26
12-30 44 1560255 2-34 49 4-122 34 1564515 9-3 23
1557546 4-7 8 1560447 4-59 8 4-143 3 1564526 3-39 9
4-11 21 1560448 4-59 2 4-143 5 8-7 7
1557547 3-11 3 1560671 1-21 2 4-143 6 8-11 8
3-17 1 1560681 9-27 15 4-143 7 8-15 7
3-19 1 9-29 10 4-145 3 8-19 8
1557551 3-11 2 9-31 15 4-145 5 8-25 4
3-17 4 9-33 13 4-145 6 1564529 1-9 25
3-19 2 9-35 13 4-145 7 1-13 25
1557560 3-17 9 1561005 7-15 4 4-145 8 1564670 2-49 9
1557565 3-17 15 1561015 1-3 25 4-145 9 2-55
3-19 15 1-5 35 4-147 1 1564747 9-15 11
1557566 3-17 3 1561117 4-123 4 1563207 1-35 4 9-17 5
1557608 3-13 1 4-123 7 1-37 2 9-19 11
3-29 1561146 4-98 3 1563208 1-35 9-21 5
1557609 3-13 1 4-117 4 1-37 2 1564752 3-37 10
3-23 4-117 5 1-39 7 1565076 4-59 12
1557709 5-15 4-117 6 1563210 1-27 13-5 5
5-19 4-117 17 1-35 1565125 4-59 9
1557711 5-15 4-117 18 1563211 1-27 1565127 5-7 1
5-19 4-117 19 1-29 5-9 1
1557737 2-31 5 4-121 4 1-35 1565135 5-15 21
1558156 4-151 8 4-121 5 1563215 1-23 1 5-21 21
1558219 1-21 16 4-121 6 1-27 5-53 25
1558226 4-115 19 4-121 20 1-29 4 5-59 25
1558227 4-112 24 4-121 21 1563216 1-23 2 1565195 2-31 10
4-121 7 4-122 22 1-25 2 13-3 2
1558515 5-19 24 1561559 13-5 4 1563217 1-23 2 1565201 3-6 2
5-25 24 13-6 2 1-25 7 1565324 6-3 11
5-27 14 1561749 13-9 1 1563222 1-23 1 6-15
5-57 28 1561755 13-5 4 1563224 1-27 4 1565325 6-15 4
5-62 28 13-6 2 1-29 2 1565327 6-3 11
5-65 8 1561759 4-12 35 1-33 2 6-15 2
1558807 2-43 11 4-61 11 1563225 1-27 4 1565382 4-12 31
1559451 9-67 14 1561871 4-7 28 1-29 2 1565453 2-31 7
1559452 9-67 14 4-11 22 1-33 9 1565832 2-27 5
1559557 3-11 4 1562088 4-12 34 1563227 1-27 8 2-29 5
©2011 HYSTER COMPANY See Service Manual 15-23
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1566116 4-128 21 1568749 3-13 9 1573177 11-8 22 9-55 11

4-131 13 1568839 3-23 20 12-21 13 9-57 10
4-136 18 3-25 15 1573549 4-25 5 9-59 11
4-140 25 3-29 3 1573599 12-7 1 1578712 9-47 2
1566117 4-128 22 3-33 18 12-7 1 1578713 9-27 2
4-131 13 1568844 3-23 27 1573601 12-7 1 9-29 15
4-136 20 3-29 40 1573602 12-7 1 9-31 2
4-140 26 1568853 3-23 22 12-7 1 9-33 6
1566146 4-105 8 3-25 13 1573606 12-7 1 9-35 6
4-108 27 3-29 5 12-7 1 9-51 2
4-111 12 3-33 16 1573675 8-8 39 9-53 2
4-115 14 1568998 3-9 9 8-12 39 9-55 3
4-122 28 1569079 2-9 4 8-15 31 9-57 2
1566169 5-19 7 2-13 4 8-19 30 9-59 3
5-25 7 1569080 2-21 1 8-21 1578714 9-35 15
5-57 26 1569527 8-15 31 1573774 1-9 15 9-47 12
5-62 26 8-19 30 1-13 15 9-53 2
1566329 5-3 2 8-21 1573776 1-19 9 9-55 2
1566420 4-11 9 1569540 2-33 29 1574162 12-9 1 9-57 2
4-11 9 1569602 9-29 4 12-9 1 9-59 2
1566453 1-35 4 9-47 9 1574164 12-9 1 1578715 9-39 8
1-37 2 1569616 8-27 19 1574165 12-9 1 9-43 10
1566457 5-54 8-29 2 12-9 1 9-61 4
1566458 4-56 1 1569751 7-9 35 1574169 12-9 1 9-63 4
1566459 4-56 2 1569768 5-54 54 12-9 1 1578718 9-53 3
1566528 2-3 18 5-60 54 1574286 2-9 35 1578746 9-23 7
1566564 12-30 1569912 6-4 40 2-17 32 9-36 1
1566654 2-37 10 1569913 6-4 40 1578453 9-17 1 1578747 9-27 18
1566700 7-15 1569914 6-4 40 1578454 9-15 1 9-31 18
1566726 1-21 7 1569915 6-4 40 9-21 1 1578750 9-43 10
1566792 9-65 10 1569995 4-148 2 1578517 2-55 9-61 4
1566853 1-21 11 1570264 9-3 4 1578518 2-55 1578815 9-23 4
2-31 11 1570298 8-7 29 1578519 2-55 9-27
1566890 9-3 21 8-15 29 1578520 2-55 1578825 2-4 27
1566951 1-63 11 1570300 8-11 26 1578521 2-55 1578873 2-4 27
1566953 1-63 10 8-19 25 1578522 2-55 1578875 9-47 7
1567032 1-9 32 1570303 9-65 6 1578617 2-33 21 1578876 9-47 11
1-13 32 1570327 4-122 37 1578619 2-33 23 1578878 9-51 12
1567475 3-3 3 1570360 5-15 4 1578620 2-33 9 9-53 10
3-5 3 5-21 4 1578660 4-11 4 9-57 9
1567693 9-3 1 5-31 22 1578704 9-39 5 1578882 9-51 7
9-7 5-53 4 9-43 6 9-53 8
1568075 8-7 22 5-59 4 9-61 1 9-55 8
8-15 21 5-69 22 1578705 9-29 11 9-57 7
1568076 8-11 24 1570597 2-41 6 9-35 14 9-59 8
8-19 23 1571610 1-19 8 1578707 9-23 3 1578883 9-51 8
1568077 8-12 45 1571640 2-9 20 9-29 2 9-53 9
8-19 36 1571673 5-35 9-36 3 9-55 9
1568253 8-12 49 5-47 9-61 2 9-57 8
1568256 8-11 25 1571797 1-19 1 1578710 9-49 3 9-59 9
8-19 24 1572111 2-33 15 1578711 9-51 13 1578886 9-53 3
1568271 7-9 22 1572583 3-13 29 9-53 11 1578887 9-51 14
15-24 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1578888 9-47 8 1579677 3-9 29 5-41 8 5-41 7

1578889 9-51 6 1579837 1-9 8 5-43 8 5-43 7
9-53 6 1-13 8 5-45 8 5-45 7
9-55 6 1579908 7-7 5-47 8 5-47 7
9-57 6 1580027 2-3 16 5-49 8 5-49 7
9-59 6 1580028 2-3 14 5-51 8 5-51 7
1578904 9-47 5 1580029 2-3 22 1581099 5-33 9 1581114 5-45 3
1578905 9-51 5 1580092 2-3 20 5-35 9 1581115 5-45 21
1578906 9-53 7 1580097 9-23 2 5-37 9 1581116 5-33 2
9-55 7 9-27 24 5-39 9 5-45 2
1578907 9-57 3 9-29 3 5-41 9 1581117 5-33 18
9-59 7 9-31 25 5-43 9 5-45 19
1578908 9-47 1580099 9-51 11 5-45 9 1581193 8-12 49
1578909 9-41 1580131 9-23 3 5-47 9 1581295 7-9 1
9-47 9-36 9 5-49 9 1581302 3-13 11
1578910 9-47 9-61 3 5-51 9 1581438 3-3 8
1578911 9-47 6 9-63 3 1581100 5-33 10 3-5 8
9-51 13 1580132 9-47 14 5-35 10 1581439 3-3 10
1578912 9-51 1580136 2-3 21 5-37 10 3-5 10
9-53 2-3 21 5-39 10 1581556 3-23 2
9-55 12 1580146 9-23 1 5-41 10 3-29 18
9-57 11 1580147 9-33 5 5-43 10 11-28 24
9-59 12 9-35 5 5-45 10 12-30 14
1578922 8-19 40 1580148 9-23 1 5-47 10 1581557 3-29 45
1578931 2-9 1 1580151 9-61 4 5-49 10 3-33 23
2-13 1 9-63 4 5-51 10 10-17 7
2-17 1 1580155 9-36 2 1581104 5-33 3 1581558 11-3 4
1578940 9-27 1 1580156 9-36 2 1581105 5-37 18 11-3 19
9-29 22 1580293 1-3 7 5-39 18 12-13 12
9-31 1 1580652 1-3 16 5-41 18 1581559 3-23 16
1578943 9-27 4 1-5 3 5-49 19 3-25 20
9-29 20 1580682 9-3 3 1581106 5-33 21 3-29 32
9-31 4 1580694 9-29 2 5-35 20 3-33 14
1578974 2-9 11 9-31 19 5-37 22 10-17 22
2-13 11 1580695 9-29 2 5-39 21 11-7 16
2-17 9 9-31 22 5-45 20 11-28 37
1578977 2-9 18 1580696 9-29 2 5-49 20 12-9 16
2-13 18 9-31 23 5-51 19 12-21 4
2-17 12 1580697 9-29 2 1581107 5-33 17 12-21 14
1579136 2-41 9 9-31 20 5-35 18 12-30 41
1579235 2-9 12 1580698 9-29 2 5-37 17 1581560 11-28 12
2-13 12 9-31 21 5-39 17 12-29 7
2-18 34 1580759 9-51 10 5-41 17 1581562 11-28 25
1579240 2-9 18 1580760 9-51 9 5-43 17 12-30 15
2-13 18 1580788 1-63 28 5-45 18 1581563 10-17 16
2-18 35 13-8 5-47 18 10-17 16
1579242 2-9 11 1581055 1-55 1 5-49 18 10-23 3
2-13 11 1-57 25 5-51 18 10-23 15
2-17 9 1581098 5-33 8 1581108 5-33 7 10-27 4
1579244 2-9 19 5-35 8 5-35 7 10-29 7
2-13 19 5-37 8 5-37 7 10-31 15
2-17 12 5-39 8 5-39 7 11-28 32
©2011 HYSTER COMPANY See Service Manual 15-25
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

11-33 10 11-3 18 9-41 7 13-13 7

11-35 5 12-13 10 9-45 8 1582465 4-15 6
11-37 9 1581586 10-8 38 1581859 9-27 17 4-15 7
11-39 9 12-30 26 9-29 9 4-17 7
12-13 9 1581587 12-30 21 9-31 17 4-19 6
12-30 22 1581588 10-7 14 9-33 12 1582474 3-23 26
12-30 36 11-3 3 9-35 12 1582511 8-27 6
12-30 36 12-13 13 1581861 9-27 12 8-29 13
12-37 3 1581589 11-7 18 9-29 14 1583601 2-34 52
12-37 8 11-12 23 9-31 12 1583602 2-34 52
12-41 4 12-21 18 1581862 9-47 3 1583611 1-3 29
12-43 7 1581590 10-5 10 1581885 3-23 3 1-5 33
12-45 15 11-29 47 3-29 16 1-9 10
1581564 9-65 3 12-9 17 1581887 3-29 7 1-13 10
10-17 34 12-30 45 3-33 26 1-15 1
11-7 17 1581592 12-21 5 1581888 3-29 8 1-21 15
11-12 22 1581594 10-17 21 3-33 21 2-9 3
12-9 15 10-17 35 1581896 10-8 35 2-13 3
12-21 3 11-28 27 10-21 9 2-17 3
1581565 10-17 28 11-28 36 11-8 25 2-21 5
11-29 45 12-30 40 11-12 25 8-15 14
12-21 8 1581670 4-59 15 12-7 9 8-19 7
12-29 4 13-5 1 12-22 26 9-15 7
1581566 10-7 13 1581733 3-23 4 1581898 3-23 13 9-17 3
11-4 20 3-25 25 3-25 3 9-19 7
11-4 22 3-29 12 3-29 24 9-21 3
11-4 29 3-33 35 3-33 3 13-7 3
11-7 3 1581739 3-23 9 13-15 5 13-9 6
11-11 3 3-25 24 1581899 3-23 35 1583769 2-25
1581567 1-15 4 3-29 9 3-29 20 2-33 20
10-17 8 3-33 34 1582072 1-9 30 1583915 8-25 1
12-30 27 13-15 2 1-13 30 1584060 1-25 8
1581577 10-17 31 1581740 3-23 10 1582161 9-3 7 1584091 3-29 10
12-29 3 3-29 21 1582218 4-123 6 1584617 1-3 28
1581578 12-21 9 1581741 11-28 20 4-123 8 1584631 1-35 5
1581579 3-23 28 12-29 10 1582222 2-3 9 1-37 6
3-25 12 1581743 10-17 6 1582286 1-3 19 1584632 1-43 9
3-29 36 1581761 3-21 7 1582287 1-3 20 1584638 1-43 11
3-33 12 1581762 3-21 1 1582299 7-9 38 1585183 2-54 37
12-30 16 1581763 3-21 2 1582300 3-37 14 1585529 4-5 3
1581580 11-4 28 1581764 3-21 3 1582301 3-37 13 1585575 8-7 18
11-7 4 1581848 3-29 42 1582337 4-52 1 8-11 22
1581582 11-7 6 3-33 31 1582370 1-3 5 8-15 18
11-11 4 9-65 4 1-5 17 8-19 21
11-28 26 1581849 11-29 42 1582464 2-29 19 1585581 1-5 7
1581583 3-23 12 1581852 1-25 14 4-5 4 1585590 1-3 4
3-25 4 1-33 13 4-17 6 1-5 16
3-29 26 1-39 12 4-19 4 1585592 1-5 36
3-33 4 9-65 11 4-19 4 1585747 3-21 6
10-7 21 10-5 9 4-52 3 1585748 3-21 5
11-3 17 1581858 7-7 37 4-61 3 1585750 5-53 33
1581585 10-7 11 9-31 24 13-11 1 5-59 33
15-26 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

5-69 12 1590098 4-53 1 1593434 1-23 11-33 10

1585751 3-21 4 1590173 4-7 1 1593435 1-27 1 12-30 35
1585835 1-9 21 1590201 2-37 5 1-29 12-30 35
1-13 21 1590368 4-7 1 1593436 1-27 1 12-37 3
3-23 11 4-7 11 1-29 12-37 8
3-29 25 4-11 3 1593913 2-41 7 1597443 10-27 5
1586013 2-27 7 1590389 3-25 38 1593914 2-41 10 10-29 8
2-29 7 1590397 2-31 1 1594314 6-3 30 10-31 16
3-13 6 1590399 2-31 1 6-7 4 11-35 6
3-13 6 1590839 5-73 8 6-9 4 11-37 10
3-25 30 5-74 13 1594804 1-63 16 11-39 10
1586020 9-49 7 1590865 5-73 7 1594805 1-63 16 12-41 5
1586022 3-29 44 5-74 10 1594806 1-63 16 12-43 8
3-33 32 1590866 5-73 6 1594950 8-7 20 12-45 16
3-33 38 5-74 11 8-11 16 1597451 4-22 6
1586109 7-2 4 1591181 4-31 5 8-15 19 1597456 11-8 23
1586279 9-47 15 4-33 3 8-19 16 12-21 15
9-49 14 4-35 2 1595168 1-19 2 1597467 1-9 36
1586280 9-47 10 4-39 3 1595169 1-19 4 1-13 36
1586428 4-59 14 4-44 2 1595170 1-19 3 1597705 2-49 1
13-5 6 4-47 11 1595234 4-22 4 1597842 2-31 2
1586430 4-22 2 4-47 11 1595425 5-33 1597852 10-17 17
1586439 1-63 17 4-49 11 5-35 1597853 10-17 14
1586440 1-63 18 4-49 11 5-37 11-28 38
1586495 1-10 45 4-51 11 5-39 12-30 42
1-14 45 1591185 4-33 5-41 1598091 8-27 7
1-21 4 4-35 1 5-43 8-29 10
4-59 13 4-35 1 5-45 1598092 1-9 36
13-5 10 4-35 1 5-47 1-13 36
1586627 8-7 5 4-35 1 5-49 1598221 4-31 5
8-11 5 1591480 3-9 4 5-51 4-33
8-15 5 1591481 3-9 19 1595426 5-33 4-33
8-19 5 1591652 1-23 4 5-37 4-33
9-15 22 1-27 10 5-41 4-35
9-17 13 1-29 8 5-45 4-35
9-19 23 1-35 7 5-49 4-35
9-21 14 1-37 3 1595427 5-33 20 4-35 1
9-69 9 1591666 2-31 9 5-45 21 4-35 1
1586759 4-59 11 1591677 2-33 1595428 5-41 20 4-35 1
13-5 9 2-37 5-43 19 4-39
1586815 1-15 2 2-41 1595731 4-22 3 4-39
1587567 1-9 22 2-43 1595808 6-3 2 4-39
1-13 22 2-47 1596179 8-22 4-39 1
1587569 1-9 31 2-49 1596180 8-22 4-39 1
1-13 31 2-53 1597381 9-65 1 4-39 1
1589377 1-61 4 2-57 1597442 10-17 17 4-43
1589397 1-61 5 1593331 4-5 15 10-17 17 4-43
1589437 1-61 7 1593334 1-25 23 10-23 3 4-43
1590033 8-8 37 1-45 24 10-23 15 4-43
8-11 37 1593427 1-27 1 10-25 3 4-43
8-15 30 1593428 1-27 1 11-28 31 4-43
8-19 29 1593433 1-23 11-28 31 4-43 1
©2011 HYSTER COMPANY See Service Manual 15-27
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

4-44 1 4-39 1 1603236 4-25 3 1608822 6-3 2

4-44 1 4-39 6 4-127 9 1608857 4-63 1
4-44 1 1598225 4-47 12 4-131 4 4-69 1
4-44 1 4-47 12 4-135 8 4-75 1
4-44 1 4-49 12 4-139 18 4-121 18
1598222 4-31 2 4-49 12 4-147 2 1608876 1-5 12
4-33 4-51 11 4-151 6 1608877 1-3 8
4-33 1598499 2-3 1 4-153 6 1-5 13
4-33 1598504 1-23 3 1603701 1-25 10 1608879 1-3 3
1598223 4-31 5 1-25 10 1-33 12 1-5 15
4-33 1-27 5 1605479 9-69 8 1609864 13-19 2
4-33 1-29 3 1605990 1-16 5 1610746 5-74 4
4-33 1-33 12 1606531 6-3 11 1610853 1-3 32
4-33 1-35 3 6-15 1610854 1-3 32
4-35 1-37 7 1606544 4-25 4 1611061 11-11 13
4-35 1 1-40 16 4-59 18 12-22 32
4-35 1599205 1-21 1 1606659 1-3 31 1611442 2-13 20
4-35 1599211 1-21 1 1606735 4-25 6 1611444 2-17 24
4-35 1 1599321 10-17 14 1606802 13-15 3 1611564 13-19 3
4-35 1 11-28 38 1606823 13-15 19 1611835 5-15 1
4-35 1 1599322 12-30 42 1606909 13-15 1 5-21 1
4-39 1599337 4-98 3 1606910 13-15 6 5-53 3
4-39 4-101 3 1607369 9-8 6 5-59 3
4-39 4-103 5 1607548 4-117 4 5-73
4-39 4-161 7 4-117 5 1611925 11-27 4
4-39 1599415 1-21 4-117 6 1611928 11-27 4
4-39 1 1599434 10-17 5 4-117 17 1611931 11-27 4
4-39 1 1600126 1-35 5 4-117 18 1612103 1-35
4-39 1 1-37 6 4-117 19 1612104 1-35
4-43 1600190 4-15 2 4-121 4 1612223 4-21 4
4-43 4-17 2 4-121 5 1612399 4-21 6
4-43 4-19 3 4-121 6 1612916 5-16 51
4-43 1600496 1-3 11 4-121 20 5-22 51
4-43 1 1-5 26 4-121 21 5-27 17
4-43 1600513 1-9 36 4-122 22 5-54 50
4-43 1-13 36 1607743 4-107 8 5-60 50
4-43 1600559 1-9 36 4-111 10 5-65 29
4-43 1 1-13 36 4-115 11 1612917 5-16 50
4-44 1 1600925 2-50 29 4-118 23 5-22 50
4-44 1 1601965 6-21 9 4-122 27 1612918 5-16 49
4-44 1 1601966 6-21 6 1607839 4-108 24 5-22 49
4-44 1 1601967 6-21 2 4-112 32 5-27 16
4-44 1 1601968 6-4 42 4-115 17 5-54 49
1598224 4-33 6-21 4-118 32 5-60 49
4-33 6 1603021 4-25 3 4-122 34 5-65 28
4-39 4-127 9 1608395 6-5 60 1613470 5-73 11
4-39 4-131 4 1608396 6-5 60 5-74 4
4-39 4-135 8 1608397 6-5 60 1613695 5-15 1
4-39 4-139 18 1608398 6-5 60 5-21 1
4-39 1 4-147 2 1608403 6-5 61 5-53 3
4-39 4-151 6 1608412 3-37 7 5-59 3
4-39 1 4-153 6 3-39 5-73
15-28 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1613749 3-23 5 4-44 1 1623558 6-17 25 1623651 6-11 13

3-25 26 4-44 1 1623559 6-17 25 1623652 6-11 12
3-29 13 4-44 1 1623560 6-18 25 1623654 6-11 3
3-33 36 4-44 1 1623561 6-18 25 1623655 6-11 26
1613755 3-23 6 4-44 1 1623562 6-18 25 1623656 6-11 10
3-25 27 4-44 1 1623563 6-18 25 1623657 6-11 9
3-29 14 1619997 9-19 1 1623564 6-18 25 1623658 6-11 4
3-33 37 1620023 8-22 1623565 6-18 25 1623659 6-11 11
1613763 3-23 7 1620024 8-22 1623566 6-18 25 1623660 6-11 25
3-29 15 1620142 3-7 3 1623567 6-18 25 1623663 6-12 36
1614069 10-31 26 1620144 3-7 4 1623568 6-17 23 1623664 6-12 36
12-45 17 1620145 3-7 2 1623569 6-17 21 1623665 6-11 5
1615173 9-7 1 1622610 10-23 8 1623570 6-17 21 1623666 6-11 6
1615240 9-65 9 10-25 8 1623571 6-17 21 1623667 6-11 8
1615652 6-4 57 11-33 8 1623572 6-17 20 1623668 6-11 2
1615671 3-29 1 12-37 9 1623573 6-17 19 1623669 6-23 23
3-33 30 1622887 5-28 44 1623574 6-17 18 1623670 6-23 22
1615804 5-27 31 5-69 1 1623575 6-17 8 1623671 6-23 21
5-65 22 1622888 5-27 11 1623576 6-17 22 1623672 6-23 18
1615817 2-25 1 5-65 5 1623577 6-17 24 1623673 6-23 16
1615818 2-25 4 1622935 13-23 5 1623578 6-17 7 1623674 6-23 14
1615920 2-25 2 13-25 5 1623579 6-17 16 1623675 6-23 15
1615956 3-25 18 13-31 6 1623580 6-17 9 1623676 6-23 13
3-33 27 13-33 6 1623581 6-17 10 1623677 6-23 12
1616122 4-7 31 13-37 5 1623582 6-17 17 1623678 6-23 11
1616222 4-21 5 13-39 6 1623583 6-17 15 1623686 6-23 1
1616379 1-5 4 1622936 13-27 7 1623584 6-17 13 1623687 6-23 2
1616384 4-148 1 13-43 7 1623585 6-17 14 1623688 6-23 3
1616386 4-148 1 13-45 7 1623586 6-17 12 1623689 6-23 4
1616388 4-148 1 1623057 4-101 3 1623587 6-17 11 1623690 6-23 5
1616390 4-148 1 4-103 5 1623588 6-17 2 1623691 6-23 6
1616764 1-3 1 4-161 7 1623589 6-17 3 1623692 6-23 9
1616768 1-3 1 1623092 2-27 13 1623590 6-17 4 1623694 6-23 24
1617080 4-5 23 1623093 2-29 16 1623591 6-17 5 1623695 6-23 20
1617083 9-3 10 1623280 4-151 1 1623592 6-17 6 1623696 6-23 19
1618227 2-3 1 4-153 1 1623593 6-17 1 1623697 6-23 17
1618395 3-3 15 1623281 4-151 1 1623633 6-12 35 1623710 2-9 31
1618437 10-17 23 4-153 1 1623634 6-12 34 2-13 30
11-28 35 1623544 6-11 22 1623635 6-12 32 2-17 28
12-30 39 1623545 6-11 21 1623636 6-12 31 2-21 34
1618500 4-7 11 1623546 6-18 32 1623637 6-12 33 1623711 2-9 8
1618503 4-7 3 1623547 6-18 31 1623638 6-12 30 2-13 8
1618978 4-5 12 1623548 6-18 30 1623639 6-12 29 2-17 8
1618992 1-9 13 1623549 6-18 29 1623640 6-12 28 2-21 36
1-13 13 1623550 6-18 28 1623641 6-12 27 1623817 6-17 8
1619518 13-8 3 1623551 6-18 27 1623642 6-11 24 1623819 2-17 4
1619962 4-35 1 1623552 6-18 26 1623643 6-11 23 2-21 1
4-35 1 1623553 6-17 25 1623645 6-11 19 1623821 2-17 4
4-35 1 1623554 6-17 25 1623646 6-11 18 2-21 1
4-35 1 1623555 6-17 25 1623647 6-11 17 1623823 6-12 36
4-43 1 1623556 6-17 25 1623648 6-11 16 1623824 6-12 36
4-44 1 1623557 6-17 25 1623650 6-11 14 1623825 6-11 8
©2011 HYSTER COMPANY See Service Manual 15-29
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1623826 6-11 2 1624501 5-15 26 1625290 1626676

1623836 5-19 19 5-21 26 1625291 1626677
5-25 19 1624504 5-25 1 1625292 1626678
5-28 46 5-57 1 1625293 1626679
5-57 23 5-61 1 1625294 1626680
5-62 23 1624505 5-15 6 1625295 1626681
1623837 5-19 19 1624507 5-53 7 1625296 1626682
5-28 46 1624589 11-31 20 1625297 1626683
1623860 2-38 21 12-34 20 1625298 1626727 4-63 5
1623891 6-7 6 13-29 8 1625299 4-66 38
6-9 6 13-35 3 1625300 4-69 4
6-9 6 13-43 15 1625301 4-72 38
1623892 6-7 7 1624590 11-31 10 1625302 4-75 4
6-9 7 12-33 10 1625303 4-78 40
6-9 7 13-29 6 1625304 4-81 4
1623893 6-7 6 13-35 2 1625305 4-84 40
6-9 6 13-43 13 1626009 4-87 10
1623894 6-7 7 1624654 9-7 2 1626010 4-87 12
6-9 7 1624657 9-7 3 1626011 4-88 18
1623895 2-34 40 1624663 9-7 1626012 4-89 34
1623904 8-7 8 1624853 9-11 3 1626013 4-93 12
8-11 9 9-13 3 1626014 1626984 4-7 7
8-15 8 1624856 9-11 9 1626015 1627106 8-3
8-19 9 1624861 9-11 6 1626016 1627107 8-3
1623905 1-3 30 9-13 6 1626353 6-7 12 1627110 8-5
1623917 2-34 39 1624862 9-11 4 6-9 9 1627111 8-5
1624117 4-5 14 9-13 4 1626478 4-22 9 1627114 8-3 6
1624185 4-5 9 1624863 9-11 5 10-7 10 1627115 8-3 6
1624189 9-4 33 9-13 5 10-7 15 1627116 8-5 6
1624204 2-27 16 1624864 9-11 1 1626490 10-8 39 1627117 8-5 6
5-3 1 1624865 9-11 2 12-22 33 1627118 8-3 7
1624401 5-15 36 9-13 2 1626519 2-33 5 1627119 8-5 10
5-21 36 1624866 9-11 10 1626656 1627120 8-3 8
5-27 10 9-13 10 1626657 1627124 8-3 1
5-53 38 1624867 9-11 11 1626658 1627125 8-3 1
5-59 38 9-13 11 1626659 1627128 8-5 1
5-65 4 1624868 9-11 1626660 1627129 8-5 1
1624405 5-15 37 9-13 1626661 1627171 6-7 9
5-21 37 1624869 9-11 8 1626662 1627183 2-43 2
5-53 39 9-13 8 1626663 1627196 2-53 1
5-59 39 1624870 9-11 8 1626664 1627199 2-54 42
1624406 5-27 9 9-13 8 1626665 1627200 1-61 6
5-65 3 1624905 9-3 12 1626666 1627227 2-27 3
1624407 5-15 40 1624917 1-9 39 1626667 2-29 3
5-54 42 1-13 39 1626668 1627345 2-27 11
1624408 5-27 34 1624992 9-11 8 1626669 2-29 11
5-65 12 9-13 8 1626670 1627350 2-49 12
1624414 5-21 41 1625255 4-22 1 1626671 1627351 2-49 12
5-60 1625286 1626672 1627354 2-49 23
1624415 5-15 31 1625287 1626673 1627364 9-7 4
5-21 31 1625288 1626674 1627422 4-5 6
5-60 1625289 1626675 1627453 5-28 45
15-30 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

5-69 36 9-51 1 5-69 1640776 1-15 4

1627465 5-27 3 1629198 9-39 4 1636634 5-65 1640818 4-7 15
5-69 37 9-43 4 5-69 4-11 19
1627639 1-35 9-53 1 1636639 5-65 1 4-55 4
1-37 1629200 9-49 8 1636640 5-31 14 1641354 6-12 37
1627788 6-17 21 1629201 9-49 1 5-69 14 1641356 6-12 37
1627789 6-17 21 1629209 9-47 13 1636643 5-31 29 1641361 6-17 21
1627790 6-17 21 1629210 9-47 4 1636644 5-27 5 1641362 6-18 33
1627791 6-17 22 1629211 9-47 16 1636645 5-27 40 1641368 4-5 3
1627792 6-17 24 1632294 4-7 9 5-69 10 1641371 2-33 5
1627793 6-17 2 4-11 16 1636803 2-33 27 1641394 13-9 2
1627794 6-17 3 1632297 3-17 7 1637158 9-4 32 1641492 2-49 8
1627799 6-12 35 1632298 3-17 7 1637397 8-29 28 1641555 8-7 28
1627802 6-11 20 1632299 3-17 7 1637399 8-25 9 1641556 8-15 28
1627804 6-11 15 1632300 3-17 8 1638706 4-5 3 1641557 8-7 28
1627805 6-11 14 3-19 10 1638793 5-31 11 1641627 2-3 19
1627806 6-11 13 1632301 3-17 10 5-69 34 1641629 2-4 23
1627812 6-11 10 1632302 3-17 11 1638795 5-27 1641953 8-5
1627813 6-11 11 1632303 3-17 12 5-31 1641954 6-5 59
1627817 6-11 5 1632304 3-17 13 1638796 5-27 8-5
1627822 6-23 11 3-19 5 5-31 1641955 6-4 59
1627823 6-23 1 1632305 3-17 14 1638799 5-31 6 8-3
1627826 6-23 8 3-19 4 1638844 12-22 1641956 6-5 59
1627836 6-23 17 1632306 3-19 15 1639068 5-59 7 8-3
1627837 6-23 7 1632307 3-17 1639069 5-21 6 1643341 10-23 15
1627838 6-23 10 1632571 5-7 12 1639154 11-7 5 11-33 10
1628117 2-33 4 5-9 12 12-21 6 1643342 2-13 24
1628746 9-27 16 1632741 5-21 39 1639679 2-3 11 2-21 13
9-31 16 5-27 6 1639704 9-4 31 1643378 8-5 6
9-33 14 5-54 41 1639801 8-11 27 1643379 8-5 6
1628747 9-23 5 5-59 41 8-19 26 1643380 8-3 8
9-33 1 5-65 2 1639845 2-3 11 1643387 8-3 6
1628748 9-23 6 1633297 6-21 8 1639847 2-4 25 1643388 8-3 6
9-33 2 1633693 9-43 5 2-4 25 1643399 8-5 7
1629158 9-49 13 9-57 1 1639849 2-4 25 1643572 1-3
1629159 9-49 6 1634047 4-59 16 1639862 5-37 3 1643681 10-23 3
1629160 9-49 4 1635218 8-5 7 5-39 3 10-25 3
1629161 9-49 11 1636046 9-11 1 5-49 3 10-27 3
1629162 9-49 10 1636047 2-38 30 5-51 3 10-29 9
1629163 9-49 2 1636048 2-37 8 1639863 5-49 21 10-31 24
9-49 9 1636120 1-23 3 5-51 20 12-37 3
1629164 9-49 12 1-25 10 1639864 5-37 20 1643702 1-3
1629165 9-49 5 1-27 5 5-39 19 1643709 9-17 10
1629166 9-53 3 1-29 3 1639865 5-41 3 9-19 15
1629185 13-19 1 1-33 12 5-43 3 1644398 4-59 17
1629196 9-39 2 1-35 3 1640531 4-7 18 1644455 6-23 4
9-41 2 1-37 7 4-11 23 1644456 6-23 10
9-43 2 1-40 16 4-55 3 1644483 12-37 3
9-45 2 1636229 9-8 1640573 5-21 40 12-41 3
9-47 1 1636626 5-65 32 5-27 8 12-43 9
1629197 9-39 3 1636630 5-69 28 5-65 10 12-45 24
9-43 3 1636633 5-65 8-29 1 1645381 8-7 21
©2011 HYSTER COMPANY See Service Manual 15-31
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

8-11 17 1646887 5-21 14 1652140 13-17 1 4-122 25

8-15 20 5-31 12 1652185 3-13 1 1655120 4-107 2
8-19 17 5-35 3-23 4-111 2
1646397 8-7 21 1646888 5-21 13 1652186 3-13 1 4-118 22
8-11 17 5-31 13 3-29 4-122 25
8-15 20 5-47 1652269 5-39 1655121 4-107 2
8-19 17 1646920 6-23 20 5-43 4-111 2
1646410 4-11 12 1647528 7-5 8 5-51 4-118 22
1646439 8-7 21 1647532 1-29 1652272 5-35 4-122 25
8-11 17 1647657 6-11 24 5-47 1655310 6-24 2
8-15 20 1648116 4-11 12 1652290 13-6 1 1655315 7-16 2
8-19 17 1648259 4-25 7 1652575 5-31 26 1655317 7-16 2
1646557 8-7 21 1648941 2-9 25 5-69 24 1655318 6-24 2
8-11 17 2-17 20 1652926 6-3 7 1655330 3-33 40
8-15 20 1649334 2-33 1653815 5-19 20 1655360 3-11 4
8-19 17 2-37 5-25 20 1655865 1-45 3
1646673 2-33 2-41 5-27 7 1-45 12
2-37 2-43 5-57 22 1-47 3
2-41 2-47 5-62 22 1-47 12
2-43 2-49 5-65 25 1656215 13-7 2
2-47 2-53 1653884 2-53 12 1656216 13-7 2
2-49 2-57 1653886 2-49 12 1656325 3-25 7
2-53 1649471 2-3 8 1653887 2-47 2 3-33 5
2-57 1649504 2-33 1653888 2-47 1 1656383 9-17 1
1646674 2-33 2-37 2-49 24 1656385 9-19 1
2-37 2-41 1654004 5-28 47 1656901 3-25 10
2-41 2-43 5-70 42 3-33 10
2-43 2-47 1654013 4-59 15 1656903 3-25 31
2-47 2-49 13-6 1657558 2-34 52
2-49 2-53 1654321 8-25 1657962 7-2 5
2-53 2-57 1654322 8-25 1 7-5
2-57 1649565 3-25 8 1654323 11-28 10 1658063 4-31 1
1646820 10-3 8 3-33 6 1654411 3-37 1 4-31 3
11-4 45 1650640 1-45 19 1654415 2-29 15 4-33 4
12-3 20 1-47 17 5-3 1 4-35 4
1646821 10-3 7 1650797 4-97 5 1654480 2-54 37 4-39 4
11-4 46 4-101 4 1654481 2-54 37 4-44 4
12-4 21 4-103 7 1654578 4-95 4 1658075 4-22 10
1646875 5-59 1650819 5-60 52 4-99 8 1658243 1-9 36
5-61 5-60 52 1654579 4-95 4 1-13 36
1646876 5-59 5-73 4 4-99 8 1658244 1-9 36
5-61 5-74 7 1654651 5-31 9 1-13 36
1646877 5-21 1651753 5-39 2 5-69 30 1660500 5-60 52
5-25 1651760 5-35 3 1654754 3-37 2 5-69 27
1646878 5-21 1651761 5-35 19 1654871 2-34 52 5-74 7
5-25 5-47 20 1654872 2-34 52 1660913 2-29 13
1646884 5-43 1651762 5-47 3 1654891 1-29 8 1661511 1-45 2
5-61 11 1651852 5-39 1-35 7 1-45 11
1646885 5-39 5-43 1-37 3 1-47 2
5-59 20 5-51 1655119 4-107 2 1-47 11
1646886 5-51 1652033 3-23 27 4-111 2 1661665 3-3 18
5-59 19 3-29 40 4-118 22 3-5 18
15-32 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1662253 3-14 1670065 11-31 5 1676151 2-9 1 4-44 1

1662420 9-15 17 12-33 5 2-13 1 4-44 1
9-17 10 13-21 11 2-17 1 4-44 1
9-19 15 13-35 17 2-21 3 1683398 4-31 1
9-21 11 13-41 13 1676400 1-3 4-31 3
1663877 2-21 18 1670194 9-15 1 1676401 1-3 4-33
1664009 3-25 1 1670195 9-15 14 1676406 1-5 11 4-33
1664014 3-33 1 1670196 9-19 13 1676453 2-33 15 4-35
1664016 3-25 10 1670292 9-17 4 1676606 7-7 4-35 1
3-33 10 1670293 9-21 4 1676923 2-34 46 4-39
1664027 3-13 1 1670332 8-21 1 2-50 27 4-39
3-25 1670333 8-21 2 1677286 1-23 4-39
1664029 3-13 1 1670334 8-21 2 1-25 12 4-43
3-33 1670413 9-25 4 1-27 4-43
1664031 3-13 1 1670431 9-23 5 1-29 4-43
3-25 9-35 1 1-33 19 4-44 1
1664033 3-13 1 1670432 9-23 4 1-40 26 4-44 1
3-33 9-29 1 1677428 1-63 10 4-44 1
1664055 3-33 39 1670434 9-23 1 1677429 3-11 4 4-44 1
1664395 9-51 12 9-29 1677432 3-11 4 1683472 13-15 3
9-55 10 1670445 9-27 8 1677528 2-3 1 1683502 13-15 6
9-59 10 9-29 5 1677530 2-3 11 1683529 9-25 1
1664495 6-3 24 9-31 8 1677600 2-3 11 1683621 9-25 2
1664496 6-3 24 1670522 9-29 21 1677648 2-4 25 1683675 2-53 3
1664499 6-4 37 1670533 9-23 6 1677649 2-4 25 1683677 2-53 13
1664500 6-4 37 9-35 2 2-4 25 1683678 2-53 12
1664940 13-17 1670677 9-15 5 1677651 2-4 25 1683720 2-54 37
1665204 5-31 30 9-19 5 1677787 3-11 4 1683721 2-54
5-74 1671271 2-34 45 1677793 3-6 2 1683722 2-54
1665205 5-31 30 2-50 26 1677833 3-6 1683744 2-54 31
5-74 1672560 1-5 20 1677876 4-7 16 1683746 2-53 29
1665746 9-17 1 1672824 2-13 34 4-55 6 1683747 2-54 35
1665747 9-21 1 2-21 7 1678165 9-63 6 1683749 2-49 3
1665748 9-19 1 1672910 2-13 25 1678166 9-41 1684085 2-49 12
1666732 1-5 2 2-21 25 9-45 1684098 2-49 12
1666746 3-5 15 1673198 5-9 15 1682755 3-25 28 1684099 2-49 12
1668335 1-19 9 1673612 6-5 75 1682758 3-33 39 1684276 2-21 30
1668688 1-19 5 1673704 13-5 2 1683379 4-31 1 1684323 3-25 23
1668689 1-19 5 1673755 13-5 3 4-31 3 1684395 1-37
1668690 1-19 5 1673981 2-31 2 4-35 1684487 9-63 6
1668691 1-19 5 1674030 1-3 30 4-35 1 1686711 1-15 2
1668692 1-19 5 1-5 32 4-35 1686719 4-19 9
1668693 1-19 5 1674131 1-3 28 4-35 1686965 3-11 4
1668694 1-19 5 1-5 30 4-39 1686966 3-11 4
1669426 2-34 53 1675581 7-2 4 4-39 1687376 3-29 43
1670054 9-23 1 1675582 7-2 4 4-39 1687377 3-23
9-29 1675583 7-2 4 4-39 3-25
1670064 11-31 4 1675655 13-8 3 4-43 1 3-29 43
12-33 4 1675726 2-50 30 4-43 3-34
13-21 12 1676093 2-18 4-43 1688059 9-8 2
13-35 12 1676122 2-21 26 4-43 1688061 9-8 5
13-41 9 1676123 2-21 27 4-44 1 1688164 4-11 12
©2011 HYSTER COMPANY See Service Manual 15-33
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1688547 3-7 4 1692176 3-21 1699141 5-27 11 12-30 42

1688551 8-5 1692203 12-33 1 5-65 5 12-37 8
1688552 8-5 1692229 8-21 1 1699754 4-93 5 12-41 1
1688555 8-3 9 1692342 13-3 1 1699988 1-15 2 12-43 1
8-5 11 1692343 13-3 1 1702466 9-23 4 12-45 14
8-25 7 1692687 12-33 1 9-31 1705597 10-23 3
1688556 8-3 9 1692911 11-31 1 1702713 2-7 10-27 3
8-5 11 1693705 2-17 11 1703472 5-27 10-29 9
8-25 7 2-21 10 5-31 10-31 24
1688557 8-5 1693950 6-5 59 1703473 5-27 12-37 3
1688558 8-5 1694398 12-33 1 5-31 1706021 12-37 8
1688561 8-5 5 1694399 12-33 1 1703474 5-65 12-41 3
1688564 8-3 1694479 11-11 14 5-69 12-43 9
1688565 8-3 12-22 23 1703475 5-65 12-45 24
1688568 8-3 1694480 12-21 23 5-69 1708054 9-63 2
1688569 8-3 1694586 2-33 1703560 10-25 3 1708262 9-41 6
1688572 8-3 5 2-37 12-30 35 9-45 7
1688803 3-25 29 2-41 1703607 8-15 31 9-63 1
1689026 2-47 8 2-43 8-19 30 1708263 9-41 5
1689455 4-39 2-47 8-21 9-55 1
4-39 2-49 1703775 4-51 11 1708298 9-45 5
4-39 2-53 1703868 4-12 31 9-55 1
4-39 2-57 1703890 1-43 8 1708299 9-45 6
4-43 1694587 2-33 1703891 1-43 1 9-59 1
4-43 2-37 1703892 1-39 4 1708317 9-41 4
4-43 2-41 1703893 1-39 5 9-45 4
4-43 2-43 1703894 1-39 5 9-51 1
4-43 1 2-47 1703895 1-40 1708365 10-29 6
4-43 1 2-49 1703896 1-40 10-31 13
4-44 1 2-53 1703897 1-40 11-37 6
4-44 1 2-57 1703898 1-39 2 11-39 8
1689459 6-11 26 1694595 12-33 1 1703899 1-39 3 12-43 6
1689460 4-39 1694596 12-33 1 1703900 1-39 1 12-45 13
4-39 1694700 1-40 27 1703901 1-39 2 1708368 10-29 5
4-39 1694830 1-25 19 1703902 1-39 3 10-31 12
4-43 1-33 18 1703903 1-39 1 11-37 5
4-43 1-40 22 1703904 1-39 6 11-39 7
4-43 1 1695078 9-11 8 1704529 4-47 13 12-43 5
4-43 1 9-13 8 4-49 13 12-45 12
4-43 1 1695082 9-11 1 4-51 12 1708371 2-3 8
4-44 1 1695160 11-31 1 1705402 6-5 75 1708373 10-31 20
4-44 1 1695566 11-31 1 1705479 13-13 4 11-39 21
1689544 3-13 11 1695670 2-21 21 1705595 10-17 14 12-45 20
1689940 3-11 4 1695754 9-63 5 10-23 15 1708691 9-7
1690958 6-24 2 1697181 4-93 8 10-27 7 1708697 9-7 1
1690995 1-27 9 1698449 4-47 9 10-29 1 1709587 4-47 8
1-29 7 4-47 20 10-31 14 4-49 8
1-33 5 4-49 9 11-28 38 4-51 8
1690996 1-23 5 4-49 20 11-33 10 1709876 1-23 1
1-25 3 4-51 9 11-35 4 1-25 4
1691525 5-9 14 4-51 19 11-37 8 1-29 4
5-13 10 1698684 3-13 28 11-39 25 1-33 6
15-34 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1709996 2-3 6 2037846 12-17 2 1-47 28 12-27

2014670 2-25 3 2037856 12-17 2 2063017 2-34 36 2066137 2-38 25
2021353 8-7 13 2037857 12-17 2 2063093 4-5 17 3-9 18
8-11 15 2037858 12-17 2 4-27 3-11 5
8-15 13 2037860 12-17 2 2063121 7-7 2066154 3-9 2
8-19 15 2038675 11-16 7 9-23 8 2066236 9-65 2
2021389 5-15 39 2038676 11-16 9-39 9 9-67
2021395 1-10 41 2038679 11-16 9-43 9 2066237 9-65 2
1-14 41 2039492 6-4 54 2063158 6-7 1 9-67
2021679 3-9 29 2039494 6-4 53 6-11 2066322 2-17 4
2021683 3-9 28 2039504 6-4 47 6-17 2-21
2021685 3-9 30 2044371 7-15 9 6-23 2066482 4-57 12
2022352 6-4 35 2044378 9-67 10 2063159 6-7 1 2066484 4-57 5
2026861 6-4 33 2044712 4-27 1 6-11 2066485 4-57 3
2027655 1-9 6 4-29 1 6-17 2067476 3-3 16
1-13 6 2046871 10-8 25 6-23 3-5 16
2028862 6-4 39 10-31 7 2063842 3-37 11 2067574 6-3 11
2029383 6-3 11 12-13 15 2063843 6-7 1 6-15 1
6-15 5 12-45 7 6-11 2067592 2-34 53
2029436 6-3 8 13-15 11 6-17 2068337 9-3 2
2033243 10-11 4 2056822 1-10 48 6-23 9-7 6
12-17 3 1-14 48 2063844 6-7 1 2068342 4-15 9
2033281 10-13 4 2056823 1-10 44 6-11 4-17 9
2033295 11-16 11 1-14 44 6-17 4-19 5
2033296 11-16 11 2056824 4-59 1 6-23 2068343 4-15 9
2033299 12-17 3 2056826 4-59 1 2063991 9-15 24 4-17 9
2033395 11-20 9 2057948 4-57 8 9-17 15 2069203 1-10 47
12-26 9 2058000 3-9 16 9-19 25 1-14 47
2034459 1-63 5 2058110 4-52 4 9-21 16 2069431 4-57 4
2035784 10-11 11 2058111 4-52 6 2064554 7-10 2069454 1-21 6
2035785 10-13 2058909 4-15 10 8-7 19 2069951 2-31 6
2035791 10-17 30 4-17 10 8-11 23 2070100 3-13 11
11-28 19 4-145 8-15 27 2070147 5-3 3
12-29 9 2060032 4-57 6 8-19 22 2070223 1-21 5
2036277 12-18 14 2060033 4-57 11 2064790 4-31 1 2070263 5-16 54
2036278 12-18 14 2060198 4-15 10 2064807 4-31 3 5-22 54
2036279 11-20 4-17 10 2064836 4-59 4 5-27 19
11-24 4-143 2064837 4-59 4 5-53 5
12-27 2060480 13-15 20 2064838 4-59 4 5-59 5
2036282 11-20 3 2060555 4-161 4 2064925 12-26 2 5-65 27
11-23 3 2060809 9-3 3 2064929 13-11 5 5-70 41
12-26 3 2060837 4-57 1 13-13 3 5-73 2
2036479 12-18 11 2061646 9-73 3 2065666 1-9 2 2070269 4-15 1
2036547 9-67 13 2062074 11-20 2 1-13 2 4-135
2036778 12-21 1 11-23 2 2065667 1-9 7 2070296 1-59 1
2037833 11-20 2 12-26 2 1-13 7 2070297 1-59 2
11-23 2 2062077 12-26 2 2065668 1-9 1 2070298 1-59 3
12-26 2 2062079 11-20 2 2065745 4-5 18 2070299 1-59 3
2037835 12-26 2 11-23 2 2065853 2-9 4 2070300 1-59 3
2037836 12-26 2 2062081 12-26 2 2-13 4 2070301 1-59 3
2037841 12-17 2 2062587 2-38 22 2065889 11-20 2070302 1-59 3
2037844 12-17 2 2062875 1-45 16 11-24 2070303 1-59 3
©2011 HYSTER COMPANY See Service Manual 15-35
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

2070304 1-59 3 2-21 11 2073395 11-20 2074022 11-16 1

2070305 1-59 3 2071619 2-17 14 12-26 11-16 1
2070306 1-59 3 2-21 8 2073397 12-26 11-16 1
2070307 1-59 3 2072157 4-7 1 2073398 12-26 11-16 1
2070531 3-3 1 2072159 4-7 31 2073402 12-26 2074042 11-16 1
3-5 1 2072188 9-3 27 2073470 5-57 23 11-16 1
3-7 2072202 2-3 3 5-62 23 2074087 11-16
2070609 9-3 27 2-3 3 2073553 11-20 2074093 11-16
2070655 1-59 2072224 9-69 13 12-26 2074126 11-16
9-19 22 2072298 3-14 30 2073566 12-26 2074138 11-16
9-21 10 3-25 37 2073570 11-20 2074167 8-7 36
2070675 3-13 8 3-34 46 2073575 12-26 8-11 36
2070677 3-13 8 2072782 3-39 3 2073626 11-20 1 2074180 12-14 26
2071008 3-13 24 2072835 11-4 32 11-20 1 2074209 1-61 10
2071011 3-13 28 11-4 32 11-23 1 2074255 1-63 9
2071012 3-13 17 2072841 11-4 32 12-26 1 2074256 1-63 9
3-21 2072865 12-22 31 12-26 1 2074320 4-52 4
2071094 7-15 2 12-22 31 2073632 12-26 1 2074622 10-11
2071097 7-9 24 2072867 12-22 31 12-26 1 2074629 10-11
7-15 2072868 12-22 31 2073634 11-20 1 2074702 3-39 1
2071181 3-37 9 12-22 31 11-20 1 2074741 1-63 24
2071197 1-9 35 2072872 12-22 31 11-23 1 2074785 8-27 2
1-13 35 12-22 31 2073636 12-26 1 2074895 10-13
2071198 1-9 34 2073024 2-7 4 12-26 1 2074901 10-13
1-13 34 2073114 1-55 3 2073681 11-20 2 2074954 10-13
2071261 1-9 3 2073115 1-55 2 12-26 2 2075005 10-11 1
1-13 3 2073116 1-55 6 2073685 12-26 2 2075011 10-11 1
3-6 3 2073117 1-55 7 2073687 11-20 2 2075089 10-13 1
13-13 1 2073118 1-55 4 2073689 12-26 2 2075095 10-13 1
2071262 1-9 14 2073119 1-55 8 2073760 4-59 6 2075101 10-13 1
1-13 14 2073121 1-55 9 4-155 2075127 10-11 2
2071327 2-3 15 2073122 1-55 10 13-5 7 2075151 10-13 2
2071329 2-37 13 2073123 1-55 11 2073762 1-9 28 2075157 10-13 2
2071330 2-37 13 2073192 8-11 21 1-13 28 2075163 10-13 2
2071501 4-11 3 2073193 7-9 1 2073768 8-27 20 2075418 1-63 23
2071517 3-13 4 2073197 1-63 4 8-29 22 2075428 1-27 10
3-25 35 2073223 11-20 2 2073852 12-17 2075442 10-11 2
3-34 44 12-26 2 2073854 12-17 2075558 5-19 23
2071560 2-37 13 2073225 12-26 2 2073857 12-17 5-25 23
2071562 2-37 13 2073226 12-26 2 2073859 12-17 5-27 13
2071579 2-34 32 2073230 12-26 2 2073888 12-17 1 5-57 27
2071595 1-9 11 2073257 11-20 1 2073890 12-17 1 5-62 27
1-13 11 11-20 1 2073891 12-17 1 5-65 7
2071596 1-9 11 11-23 1 2073895 12-17 1 2075615 1-63 22
1-13 11 12-26 1 2073912 12-17 2075656 1-63 27
2071616 2-9 17 12-26 1 2073915 12-17 2075846 5-11 1
2-13 17 2073259 12-26 1 2073919 12-17 5-13 1
2071617 2-9 15 12-26 1 2073932 12-17 1 2075911 4-31 1
2-13 15 2073260 12-26 1 2073935 12-17 1 2075912 4-31 3
2071618 2-9 17 2073261 12-26 1 2073939 12-17 1 2075913 4-31 1
2-13 17 2073264 12-26 1 2073953 11-16 2075914 4-31 3
2-17 16 12-26 1 2073992 11-16 2075916 4-31 1
15-36 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

2075917 4-31 3 12-30 31 2078054 12-30 32 12-29

2076154 3-9 22 12-30 31 12-30 32 2078206 12-3
2076168 3-13 2 12-30 31 2078056 10-17 4 12-7
3-25 32 12-30 31 10-17 4 12-9
3-33 42 12-30 31 11-28 8 12-29
2076169 1-63 22 2077921 10-16 1 2078058 12-30 32 2078223 12-3
2076255 8-27 4 10-16 1 12-30 32 12-7
8-29 12 10-16 1 2078062 10-17 4 12-9
2076256 8-27 8 10-16 2 2078109 13-29 29 12-29
8-29 14 10-16 2 13-35 29 2078226 12-3
2076429 2-41 2 10-16 2 2078110 13-29 30 12-7
2076519 5-19 19 2077927 10-16 1 13-35 28 12-9
5-25 19 10-16 1 2078111 13-41 25 12-29
5-28 46 10-16 1 2078112 13-41 24 2078230 12-3
2076527 5-57 23 10-16 2 2078113 13-21 21 12-7
5-62 23 10-16 2 2078114 13-21 20 12-9
5-66 41 10-16 2 2078116 10-3 12-29
2076695 4-57 2 2077987 10-16 1 10-5 2078243 11-3
2076763 9-73 2 10-16 1 10-16 11-7
2076765 9-69 2 10-16 1 10-16 11-11
2077239 3-3 11 10-16 2 10-16 11-27
3-5 11 10-16 2 2078122 10-3 2078273 11-3
2077442 5-7 7 10-16 2 10-5 11-7
5-9 7 2077993 10-16 1 10-16 11-11
2077444 5-7 11 10-16 1 10-16 11-27
5-9 11 10-16 1 10-16 2078279 11-3
2077588 9-3 19 10-16 2 2078158 10-3 11-7
9-11 10-16 2 10-5 11-11
2077604 8-7 21 10-16 2 10-16 11-27
8-11 17 2077999 10-16 1 10-16 2078312 1-9 39
8-15 20 10-16 1 10-16 1-13 39
8-19 17 10-16 1 2078164 10-3 2078353 2-3 3
2077746 5-11 8 10-16 2 10-5 2078413 12-29 1
5-13 8 10-16 2 10-16 12-29 2
2077747 5-7 6 10-16 2 10-16 2078415 12-29 1
5-9 6 2078039 9-39 1 10-16 12-29 2
2077809 4-7 25 2078040 9-39 2078170 10-3 2078416 12-29 1
4-11 25 2078041 9-43 1 10-5 12-29 2
4-95 2078042 9-43 10-16 2078420 12-29 1
2077810 4-7 26 2078043 9-43 1 10-16 12-29 2
4-11 25 2078044 9-43 10-16 2078437 12-29 1
4-98 2078045 9-23 1 2078199 12-3 12-29 2
2077914 10-16 3 2078046 9-23 12-7 2078440 12-29 1
10-16 3 2078047 9-23 1 12-9 12-29 2
10-16 3 2078048 9-23 12-29 2078444 12-29 1
10-16 3 2078050 10-17 4 2078201 12-3 12-29 2
10-16 3 10-17 4 12-7 2078585 11-27 1
11-28 7 11-28 8 12-9 2078589 11-27 1
11-28 7 11-28 8 12-29 2078591 11-27 1
11-28 7 12-30 32 2078202 12-3 2078625 11-27 2
12-30 31 12-30 32 12-7 11-27 2
12-30 31 2078052 12-30 32 12-9 2078631 11-27 2
©2011 HYSTER COMPANY See Service Manual 15-37
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

2078655 11-28 5 2083702 9-15 19 10-27 6 4-63

2078685 11-28 5 9-17 7 10-29 12 2086107 1-35
2078691 11-28 5 9-19 20 10-31 23 2086108 1-35
2079281 4-61 4 9-21 8 2085660 10-23 7 2086134 9-71 13
2079326 4-25 1 2083703 9-17 8 10-27 1 2086157 9-71 18
2079376 11-28 17 9-19 19 10-29 11 2086298 1-37
2079377 11-28 16 9-21 7 10-31 22 2086299 1-37
2079402 4-15 10 2083704 9-21 6 2085677 10-25 6 2086300 1-37
4-147 2083705 9-19 18 10-27 6 2086301 1-37
2079436 13-15 9 2083706 9-15 18 10-29 12 2086527 5-11 7
2079731 9-3 16 2083765 9-69 14 10-31 23 5-13 7
2079735 9-3 22 2083998 13-27 2085678 10-25 7 2086562 9-3 19
2079736 9-3 14 13-45 10-27 1 9-11
2079843 4-61 15 2083999 13-23 10-29 11 2087117 2-7 7
2080791 2-37 16 13-25 10-31 22 2087119 2-7 5
2081136 2-38 17 13-31 2085741 8-27 13 2087121 2-7 2
2081229 1-57 1 13-33 2085742 8-27 9 2087122 2-7 3
2081230 1-57 2 13-37 2085743 8-27 12 2087123 2-7 8
2081231 1-57 3 13-39 2085744 8-27 10 2087310 9-71 6
2081232 1-57 4 13-43 2085745 8-27 9 2087565 10-23 13
2081233 1-57 5 2084703 4-148 2085746 8-27 10 10-25 4
2081234 1-57 6 2084829 4-15 1 2085747 8-27 13 11-33 3
2081235 1-57 7 4-131 2085748 8-27 12 12-37 15
2081236 1-57 8 2084867 9-71 19 2085764 7-13 5 2087701 2-37 7
2081237 1-57 9 2084985 9-69 6 2085765 7-13 5 4-115
2081238 1-57 10 2085076 11-28 6 2085766 7-13 7 2087702 2-37 7
2081239 1-57 11 2085129 5-35 6 2085767 7-13 7 4-105
2081240 1-57 12 5-37 6 2085830 10-23 5 2088151 6-5 69
2081241 1-57 13 5-39 6 10-27 9 2088388 6-5 66
2081242 1-57 14 5-41 6 10-29 13 2088389 6-3 1
2081243 1-57 15 5-43 6 10-31 19 2088390 6-5 66
2081244 1-57 16 5-47 6 2085831 10-23 4 2088391 6-3 1
2081245 1-57 17 5-49 6 10-27 8 2088450 11-7 12
2081246 1-57 18 5-51 6 10-29 10 12-22 23
2081247 1-57 19 2085193 1-29 10-31 18 2088451 11-7 12
2081248 1-57 20 2085194 1-29 2085832 10-23 6 12-21 23
2081249 1-57 21 2085519 4-31 3 10-27 6 2088709 12-37 7
2081250 1-57 22 2085520 4-31 3 10-29 12 12-41 9
2081251 1-57 23 2085521 4-31 3 10-31 23 12-43 13
2081252 1-57 24 2085522 4-31 3 2085833 10-23 7 12-45 19
2081315 2-38 29 2085596 10-23 4 10-27 1 2088710 12-37 6
2081865 9-3 8 10-27 9 10-29 11 12-41 6
2082654 9-3 19 10-29 13 10-31 22 12-43 10
9-11 10-31 19 2085875 1-55 12 12-45 18
2082657 2-41 3 2085597 10-23 5 2085877 1-55 5 2088711 12-37 4
2083129 4-12 33 10-27 8 2085894 1-9 40 12-41 7
2083429 6-4 46 10-29 10 1-14 40 12-43 11
2083634 2-25 5 10-31 18 2085942 4-21 1 12-45 23
2083701 9-15 20 2085604 1-9 38 4-153 2088712 12-37 5
9-17 6 1-13 38 2085943 4-21 1 12-41 8
9-19 21 2085641 2-33 16 4-151 12-43 12
9-21 9 2085659 10-23 6 2085952 4-5 8 12-45 22
15-38 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

2088905 12-37 4 10-31 19 4-157 2093469 4-12 38

12-41 7 2089856 10-23 5 2090110 4-57 1 2093470 4-11 14
12-43 11 10-27 8 2090114 5-7 13 2093681 2-37 7
12-45 23 10-29 10 5-9 13 4-107
2088906 12-37 5 10-31 18 2090184 8-29 27 2093682 2-37 7
12-41 8 2089857 10-23 6 2090185 8-29 29 4-117
12-43 12 10-27 6 2090303 2-33 22 2094026 2-7 1
12-45 22 10-29 12 2090613 4-5 17 2094027 2-7 6
2088907 12-37 7 10-31 23 4-29 2094028 2-7 9
12-41 9 2089858 10-23 7 2090661 4-5 6 2094029 2-7 9
12-43 13 10-27 1 2090664 2-3 3 2094096 2-37 13
12-45 19 10-29 11 2090887 4-5 8 2094097 2-37 13
2088908 12-37 6 10-31 22 4-69 2094153 8-29 19
12-41 6 2089861 10-25 6 2090890 6-9 1 2094154 8-29 19
12-43 10 10-27 6 6-11 2094155 8-29 21
12-45 18 10-29 12 6-17 2094156 8-29 16
2088909 12-37 4 10-31 23 6-23 2094157 8-29 23
12-41 8 2089862 10-25 7 2090891 6-9 1 2094158 8-29 16
12-43 12 10-27 1 6-11 2094192 11-16 15
12-45 22 10-29 11 6-17 2094490 4-124 11
12-45 23 10-31 22 6-23 2094582 4-11 10
2088910 11-35 7 2089898 12-41 9 2090896 6-9 1 4-123
12-37 5 12-43 13 6-11 2095092 9-23
12-41 7 12-45 19 6-17 2095094 9-23
12-43 11 2089899 12-41 6 6-23 2095096 9-23 1
2088916 9-3 24 12-43 10 2090897 6-9 1 2095097 9-23 1
2088997 2-34 12-45 18 6-11 2095659 5-11 1
2089061 8-27 17 2089900 12-37 4 6-17 5-11 8
2089062 8-27 23 12-41 7 6-23 5-13 1
2089364 2-7 12-43 11 2091015 8-7 31 2095707 9-69 14
2089556 11-33 11 12-45 23 8-11 31 2095895 4-59 16
11-35 7 2089901 12-37 5 8-29 6 2096034 5-7 6
11-37 11 12-41 8 2091513 8-29 24 5-9 6
11-39 13 12-43 12 2091866 9-71 3 2096035 5-13 8
2089557 11-33 12 12-45 22 2091868 13-19 4 2096037 5-7 13
11-35 8 2089904 12-37 4 2091910 11-29 48 5-9 13
11-37 12 12-41 7 2091911 11-29 49 2096079 8-8 39
11-39 14 12-43 11 2092157 9-71 9 8-12 39
2089562 11-33 12 12-45 23 2092505 8-25 7 8-15 31
11-35 7 2089905 12-37 5 2092506 8-25 7 8-19 30
11-37 11 12-41 8 2092613 8-8 46 8-21
11-39 13 12-43 12 8-12 52 2097392 4-5 8
2089563 11-33 11 12-45 22 8-15 36 4-75
11-35 8 2089910 11-33 11 8-20 43 2098011 4-17 1
11-37 12 11-37 11 2092888 8-7 24 4-135
11-39 14 11-39 13 8-11 29 2098012 4-17 1
2089675 1-35 2089911 11-33 12 8-15 23 4-131
2089676 1-35 11-35 8 8-19 28 2098082 4-59 4
2089776 9-11 1 11-37 12 2093224 8-8 4-59 4
2089855 10-23 4 11-39 14 8-12 4-59
10-27 9 2090051 2-33 25 8-16 2098083 4-59 4
10-29 13 2090084 4-59 6 8-20 2098084 4-59 4
©2011 HYSTER COMPANY See Service Manual 15-39
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

2098085 4-59 4 2102129 1-29 2104542 11-20 2109871 5-13 1

2098121 2-17 24 2102314 2-9 15 11-23 2109874 5-9 7
2-21 31 2-13 15 12-26 2109875 5-9 17
2098326 9-3 16 2102565 7-7 2104544 12-26 5-13 11
2098330 1-13 1 9-23 8 2104546 12-26 2110224 8-8 39
2098385 4-59 6 9-39 9 2104550 12-26 8-12 39
4-159 9-41 8 2104701 4-19 1 8-15 31
2098414 6-3 9 9-43 9 4-139 8-19 30
2098442 3-3 5 9-45 9 2104702 4-19 1 8-21
3-5 5 2102640 1-65 1 4-127 2110791 4-47 2
2098443 3-3 17 2102904 4-57 1 2104947 11-16 4-47 3
3-5 17 2103012 9-41 2105372 4-39 1 4-47 4
2098586 2-3 15 2103014 9-45 2105373 4-43 1 4-49 2
2098588 2-3 3 2103016 9-45 2105376 4-39 1 4-49 3
2099224 4-33 1 2103017 9-41 1 2105377 4-43 1 4-49 4
2099225 4-35 1 2103018 9-45 1 2105378 4-39 1 4-49 5
2099228 4-33 1 2103019 9-45 1 2105379 4-43 1 4-51 2
2099229 4-35 1 2103360 1-23 2105380 4-39 1 4-51 3
2099230 4-33 1 2103361 1-23 2105381 4-43 1 2110792 4-47 4
2099231 4-35 1 2103364 1-29 2105382 4-43 1 4-49 5
2099233 4-33 1 2103365 1-29 2105383 4-43 1 4-51 5
2099234 4-35 1 2103366 1-29 2105384 4-44 1 2110793 4-47 3
2099235 4-35 1 2103367 1-29 2105385 4-44 1 4-49 3
2099236 4-35 1 2103676 7-13 5 2105635 4-5 8 4-51 3
2099237 4-35 1 2103806 7-13 7 4-81 2110915 3-13 9
2099238 4-35 1 2103849 4-39 1 2105803 3-13 11 2110942 4-47 19
2099393 9-15 20 2103850 4-43 1 2105887 9-23 4-49 19
9-17 6 2103853 4-39 1 2105889 9-23 4-51 18
9-19 21 2103854 4-43 1 2105891 9-23 1 2110943 4-47 18
9-21 9 2103855 4-39 1 2105892 9-23 1 4-49 18
2099394 9-15 19 2103856 4-43 1 2107382 4-59 4 4-51 17
9-17 7 2103857 4-39 1 2107383 4-59 4 2111004 4-15 2
9-19 20 2103858 4-43 1 2107384 4-59 4 4-17 2
9-21 8 2103859 4-44 1 2107524 5-9 6 4-19 3
2099395 9-17 8 2103860 4-44 1 2107969 1-25 16 2111005 4-15 12
9-19 19 2103861 4-44 1 1-33 15 4-17 12
9-21 7 2103862 4-44 1 1-40 24 4-19 3
2099396 9-21 6 2103939 6-24 1 2108024 11-31 2111754 10-31 4
2099397 9-19 18 2103940 6-24 1 2108026 11-31 10-31 4
2099398 9-15 18 2104071 7-13 5 2108029 12-33 11-39 22
2099479 2-33 16 2104072 7-13 7 2108030 12-33 12-45 4
2099951 1-40 17 2104109 13-15 4 2108032 12-33 2111755 10-31 4
2100710 4-61 3 2104429 9-71 4 2108033 12-33 12-45 4
2101429 2-37 13 2104449 9-3 19 2108034 11-31 2111769 4-47 7
2101430 2-37 13 9-11 2108037 12-33 4-49 7
2102122 1-23 2104508 11-20 2108038 12-33 4-51 7
2102125 1-23 11-23 2108249 4-47 5 2111770 4-47 17
2102126 1-27 1 12-26 2109665 5-13 1 4-49 17
1-29 2104512 12-26 2109666 4-55 1 4-51 16
2102127 1-27 1 2104514 11-20 2109698 1-63 2111796 4-51 4
1-29 11-23 2109869 5-9 13 2111799 4-47 6
2102128 1-29 2104516 12-26 2109870 5-13 8 4-49 6
15-40 See Service Manual ©2011 HYSTER COMPANY
for service procedures.
 UNIT CODE G004
05/2009 NORTH AMERICA

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

2111800 4-47 15 4006348 2-13 25 4018959 2-3 18 4601099 4-47 1

4-49 15 2-21 27 4019146 2-33 4601100 4-49 1
4-51 14 4006723 7-9 31 2-37 4601101 4-47 1
4000712 13-15 4 4006802 2-4 2-41 4601102 4-49 1
4000998 9-7 2 4007052 1-45 5 2-43 4601103 4-47 1
4001029 9-3 1 1-47 5 2-47 4601104 4-49 1
9-7 4007318 1-40 18 2-49 4601105 4-47 1
4001358 4-111 2 1-47 24 2-53 4601106 4-49 1
4-118 22 4007319 1-39 10 2-57 4601107 4-47 1
4-122 25 1-47 18 4020186 2-33 4601108 4-49 1
4002682 1-23 1 4007549 1-5 1 2-33 4601110 4-51 1
1-25 5 4007562 1-5 1 2-37 4601112 4-51 1
1-29 4007719 1-5 2-41 4601114 4-51 1
1-33 7 4007720 1-5 2-43 4601116 4-51 1
4003844 2-13 25 4007891 1-25 17 2-47 4601120 4-47 16
2-21 25 4007984 4-111 11 2-49 4-49 16
4004338 2-33 4-122 29 2-53 4-51 15
2-37 4008420 1-33 16 2-57 4601152 2-3 15
2-41 4008604 4-111 11 4020187 2-33 4601153 2-3 3
2-43 4-122 29 2-33 4601159 2-37 7
2-47 4008610 2-34 39 2-37 4-111
2-49 4009234 9-13 1 2-41 4601160 2-37 7
2-53 4009235 9-13 1 2-43 4-121
2-57 4009236 9-13 1 2-47 4601265 4-47 1
4004339 2-33 4009237 9-13 1 2-49 4601500 1-40
2-37 4009240 9-13 9 2-53 4-5
2-41 4009488 13-7 1 2-57 4-93
2-43 13-8 1 4020588 5-27 13 4601522 4-161
2-47 4009620 1-39 8 5-65 7 4601836 1-33
2-49 4011103 5-7 4 4020857 2-3 11 4601837 1-33
2-53 5-9 4 4021209 2-3 11 4602050 3-13 17
2-57 4011397 1-5 25 4022937 2-13 24 3-21
4004594 2-54 43 4011435 1-5 24 2-21 15 4602289 9-3 19
4004775 1-45 14 4013095 1-25 6 4022956 7-13 1 9-13
1-47 14 1-33 8 4022958 7-13 2 4602290 9-3 19
4004776 1-40 14 1-39 7 4023450 7-2 5 9-13
1-47 25 4013299 3-19 14 7-5 4602291 9-3 19
4005010 1-33 9 4013301 3-19 11 4025271 1-5 11 9-13
1-40 17 4013302 3-19 12 4025480 5-43 3 4602292 9-3 19
1-45 4013303 3-19 13 4025491 5-39 3 9-13
1-47 4013304 3-19 15 5-51 3 4603376 1-25
4005805 1-45 23 4013327 3-19 9 4025492 5-35 3 4603382 1-39
4005807 1-33 4013328 3-19 7 4025493 5-47 3 4603383 1-39
4005808 1-33 4013329 3-19 6 4027341 1-40 4603384 1-39
4006052 2-3 22 4013363 5-54 52 4028642 7-5 8 4603385 1-39
4006329 4-111 19 5-60 55 4600272 13-13 6 4603386 1-63
4-122 31 4015888 1-5 1 4600755 3-21 4603425 2-37 13
4006330 4-97 1 4016100 1-5 1 4601093 4-47 1 4603426 2-37 13
4-101 1 4016192 1-5 4601094 4-49 1 4603439 4-47 6
4-103 1 4016193 1-5 4601096 4-49 1 4-49 6
4006347 2-13 25 4017128 2-47 1 4601097 4-47 1 4603440 4-51 6
2-21 26 2-49 24 4601098 4-49 1 4603492 1-45 25
©2011 HYSTER COMPANY See Service Manual 15-41
for service procedures.
 UNIT CODE G004
NORTH AMERICA 05/2009

NUMERICAL INDEX (continued)

PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM

1-47 27 4-103 12-45 2 4-51 10

4603493 1-45 15 4604532 4-7 25 12-45 3 4605337 4-47 14
1-47 29 4-11 25 4604567 12-45 2 4-49 14
4603957 5-9 6 4-97 4604594 4-57 1 4-51 13
4604390 4-7 26 4604565 10-31 2 4604938 12-14 28 4606204 4-5 8
4-11 25 11-39 24 4604939 10-8 28 4-87
4-101 12-45 3 11-4 23 4609648 3-25 32
4604393 4-7 26 4604566 10-31 3 4605336 4-47 10 3-33 42
4-11 25 11-39 2 4-49 10 4612911 1-39 8

15-42 See Service Manual ©2011 HYSTER COMPANY

for service procedures.