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PARTS

MANUAL
J1.60XMT-2.00XMT
(J160)

CUSTOMER EDITION

1556469
02/2004

2004 Hyster Company

UNIT CODE J160


EUROPE

02/2004

SECTIONS

FRAME

ELECTRICAL SYSTEM

DRIVE UNIT

STEERING SYSTEM

BRAKE/ACCELERATOR SYSTEM

HYDRAULIC SYSTEM

MAST-TWO STAGE LIMITED FREE-LIFT

MAST-THREE STAGE FULL FREE-LIFT

MAST-TWO STAGE FULL FREE-LIFT

10

OPTIONS

11

NUMERICAL INDEX

This Parts Manual is divided into 11 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.

02/2004

UNIT CODE J160


EUROPE

TABLE OF CONTENTS
DESCRIPTION

PAGE

A
ACCELERATOR ASSEMBLY .............................................................................................................................. 5-2
ACCELERATOR PEDAL....................................................................................................................................... 5-4
B
BACKUP ALARM ............................................................................................................................................... 10-2
BATTERY COMPARTMENT AND COVERS ........................................................................................................ 1-2
BATTERY CONNECTOR
DIN.................................................................................................................................................................... 2-2
NON-DIN........................................................................................................................................................... 2-4
BATTERY SLIDER AND RETAINER .................................................................................................................... 1-6
BATTERY SPACER ............................................................................................................................................ 10-4
BRAKE ASSEMBLY ............................................................................................................................................. 5-6
C
CARRIAGE
THREE STAGE FULL FREE-LIFT ....................................................................................................................
TWO STAGE FULL FREE-LIFT ........................................................................................................................
TWO STAGE LIMITED FREE-LIFT...................................................................................................................
CONTACTOR PANEL ...........................................................................................................................................
COUNTERWEIGHT .............................................................................................................................................

8-2
9-2
7-2
2-6
1-8

D
DASH DISPLAY.................................................................................................................................................... 2-8
DC CONVERTER
36/48 VOLT TO 12 VOLT ................................................................................................................................ 10-6
PREMIUM ....................................................................................................................................................... 10-8
DECAL AND PLATE LOCATION ........................................................................................................................ 1-10
DRIVE TIRE AND WHEEL ASSEMBLY
SOLID PNEUMATIC ......................................................................................................................................... 3-2
DRIVE UNIT ......................................................................................................................................................... 3-4
E
ELECTRO-HYDRAULIC AUXILIARY VALVE SECTION ...................................................................................... 6-2
ELECTRO-HYDRAULIC CONTROL ................................................................................................................. 2-10
ELECTRO-HYDRAULIC CONTROL VALVE ........................................................................................................ 6-4
ELECTRO-HYDRAULIC LEVERS........................................................................................................................ 6-6
ELECTRO-HYDRAULIC MAIN CONTROL VALVE SECTION ........................................................................... 6-22
ELECTRO-HYDRAULIC TILT VALVE SECTION ................................................................................................ 6-26
EMERGENCY STOP.......................................................................................................................................... 2-12
F
FLOOR PLATES................................................................................................................................................. 1-12
FORKS ............................................................................................................................................................... 1-14
FREE LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-4
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-4
FREE LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-6
FRONT LIGHT.................................................................................................................................................. 10-10

2004 HYSTER COMPANY

See Service Manual


for service procedures.

UNIT CODE J160


EUROPE

02/2004

TABLE OF CONTENTS (Continued)


DESCRIPTION

PAGE

G
GEAR PUMP ........................................................................................................................................................ 4-2
H
HAND PUMP ........................................................................................................................................................ 4-4
HANDLEVER........................................................................................................................................................ 6-8
HEADER HOSE
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-8
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-6
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-4
HYDRAULIC GEAR PUMP ................................................................................................................................ 6-10
HYDRAULIC HOSE AND FITTINGS
ELECTRO ....................................................................................................................................................... 6-12
MANUAL ......................................................................................................................................................... 6-14
HYDRAULIC PUMP MOTOR ............................................................................................................................. 6-16
HYDRAULIC TANK ASSEMBLY......................................................................................................................... 6-18
HYDRAULIC VALVE AND ATTACHING PARTS
MANUAL ......................................................................................................................................................... 6-20
I
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-12
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-8
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6
INTEGRAL SIDE-SHIFT CARRIAGE
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-14
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-10
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-8
INTEGRAL SIDESHIFT
HYDRAULIC HOSES.................................................................................................................................... 10-12
INTERFACE CABLE......................................................................................................................................... 10-13
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-16
L
LOAD BACKREST EXTENSION........................................................................................................................ 1-16
M
MAIN LIFT ASSEMBLY
THREE STAGE FULL FREE-LIFT ..................................................................................................................
TWO STAGE FULL FREE-LIFT ......................................................................................................................
TWO STAGE LIMITED FREE-LIFT.................................................................................................................
MAIN LIFT CYLINDER
LEFT HAND
TWO STAGE FULL FREE-LIFT ..................................................................................................................
RIGHT HAND
TWO STAGE FULL FREE-LIFT ..................................................................................................................
THREE STAGE FULL FREE-LIFT ..................................................................................................................
TWO STAGE LIMITED FREE-LIFT.................................................................................................................
MAIN WIRE HARNESS......................................................................................................................................
MANUAL CONTROL VALVE ..............................................................................................................................
ii

See Service Manual


for service procedures.

8-18
9-12
7-10

9-14
9-16
8-22
7-12
2-14
6-24

2004 HYSTER COMPANY

02/2004

UNIT CODE J160


EUROPE

TABLE OF CONTENTS (Continued)


DESCRIPTION

PAGE
M (continued)

MASTER CYLINDER ........................................................................................................................................... 5-8


O
OUTER MAST
THREE STAGE FULL FREE-LIFT ..................................................................................................................
TWO STAGE FULL FREE-LIFT ......................................................................................................................
TWO STAGE LIMITED FREE-LIFT.................................................................................................................
OVERHEAD GUARD..........................................................................................................................................

8-24
9-18
7-14
1-18

P
PARKING BRAKE............................................................................................................................................... 5-10
S
SEAT................................................................................................................................................................... 1-20
SHIFT LEVER ...................................................................................................................................................... 4-6
SIDE-SHIFT CYLINDER .................................................................................................................................... 7-16
STATIC STRAP................................................................................................................................................... 1-22
STEER AXLE ....................................................................................................................................................... 4-8
STEER COLUMN ............................................................................................................................................... 4-12
STEER PUMP AND MOTOR ............................................................................................................................. 4-16
STEER TIRE AND WHEEL ASSEMBLY
SOLID PNEUMATIC ....................................................................................................................................... 4-18
T
TAIL LIGHT....................................................................................................................................................... 10-14
TILT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-26
TILT CYLINDER ATTACHING PARTS
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-28
TRACTION CONTROLLER
CONTACTOR HYDRAULIC ............................................................................................................................ 2-18
TRANSISTOR/PREMIUM ............................................................................................................................... 2-20
TRACTION MOTOR ............................................................................................................................................. 3-6
TRANSMISSION .................................................................................................................................................. 3-8
W
WORK LIGHT................................................................................................................................................... 10-16
WORK LIGHT/STROBE COMBINATION ......................................................................................................... 10-18

2004 HYSTER COMPANY

See Service Manual


for service procedures.

iii

UNIT CODE J160


EUROPE

02/2004

ABBREVIATIONS QUICK REFERENCE SHEET


Listed below are abbreviations used in parts manuals to denote the following expressions:
TERM

DEFINITION

TERM

DEFINITION

Amp

Amperes

FRE

AR

As Required

in.

inches

BDI

Battery Discharge Indicators

LPG

Liquefied Petroleum Gas

BWI

Brush Wear Indicator

MAP

Manifold Absolute Pressure

CE

Communicator End

mm

CRE

Corrosive Environment

millimeters

D/B

Date Break

MSTS

Microprocessor Spark Timing System

dbA

Decibel "A" Scale

NPT

National Pipe Threads

DE

Drive End

O/S

Oversize

ECH

Empty Container Handler

PTO

Power Take Off

ECH-3

Empty Container Handler - 3 High


Stacking

RPM

Revolutions per Minute

S/N

Serial Number

ECH-4

Empty Container Handler - 4 High


Stacking

ECH-5

Freezer Environment

TMM

Truck Management Module

UL Type D

Diesel-Powered Safety Rating

Empty Container Handler - 5 High


Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

Empty Container Handler - 6 High


Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High


Stacking

UL Type G

Gasoline-Powered Safety Rating

ECM

Electronic Control Module

UL Type GS

Gasoline-Powered Safety Rating

ECN

Engineering Change Notice

UL Type LP

Gas-Powered Safety Rating

EEPROM

Electrically Erasable Programmable


Read Only Memory

UL Type LPS

LP Gas-Powered Safety Rating

U/S

Undersize

EPROM

Electrically Programmable Read Only


Memory

UL

Underwriters Laboratory

Volts

ECH-6

iv

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HOW TO USE THE ILLUSTRATED PARTS MANUAL


This parts manual describes and illustrates assemblies,
subassemblies, and detail parts needed for service
replacement.

2004 HYSTER COMPANY

The different constructions are indicated by keys and


footnotes. The callouts correspond to descriptions
found on the next page.

See Service Manual


for service procedures.

UNIT CODE J160


EUROPE

02/2004

HOW TO FIND THE DESIRED PART NUMBER


WHEN THE PART NUMBER AND THE NEXT
HIGHER ASSEMBLY IS NOT KNOWN:

previous page, BEARING CAP (Item 2) is a


subpart of the major assembly CASE.

1. Determine the function and application of the part


required. Turn to the Sections Page. Choose the
general area of reference most likely to include
the part.

9. Quantities shown are for one assembly. The


quantities of the subpart BEARING CAP are
indicated as two and two. This means two per
CASE assembly.

2. Turn to the section you chose. Use the Section


Table of Contents to determine the assembly which
would normally contain the part required. Then
locate the part on the assembly breakdown page.

10. Serial number breaks identify the most current


parts information and are shown as follows:
S/N D001H-2628
Indicates last serial number affected.
S/N D001H-2629
Indicates the first serial number affected.
S/N D001H-1553 S/N D001H-3291
Indicates a range of serial numbers affected.

WHEN THE PART NUMBER IS NOT KNOWN


AND THE NEXT HIGHER ASSEMBLY IS
KNOWN:
3. Determine the assembly the required part is used
on. Turn to the Table of Contents on Page i.
4. Locate the assembly the required part is used on
and turn to the page indicated for that assembly.
Then locate the part on the assembly breakdown
page.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index on Page 11-1 to find the
part number. Turn to the page listed and locate the
part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers,
descriptions, quantities required, keys and
footnotes to help in selecting correct parts.
6. Five periods in the PART NO. column (. . . . .)
indicate that the part is either Not Serviced
Separately or there is a reference to another figure.
A figure reference is denoted by a pointing hand
followed by a figure number in the DESCRIPTION
column (Figure 10)
7. Keys are used to show two or more similar
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E"
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..)
indicate that the part is not used for that assembly.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and
subparts of assemblies. In the example on the
vi

ECN numbers for pending serial numbers are


shown to allow for the inclusion of the most current
parts information and are identified as follows:
S/N Pending Per ECN 63243
Indicates a pending serial number for last unit
affected.
S/N Pending Per ECN 63243
Indicates a pending serial number for first unit
affected.
Date breaks are used to indicate when a change
occurred but a subsequent serial number break
was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
follows:
D/B 3/00
Indicates that a change occurred sometime
within that month for the item affected.
D/B 3/00
Indicates that a change occurred sometime
within that month for the item affected.
D/B 3/00 D/B 4/00
Indicates a range of production dates of the
item affected.
Contact your local dealer for Hyster lift trucks for
serial number information for items with a ECN or
a date break.
ORDERING PARTS:
When ordering replacement parts, give the unit serial
number, part number, name of part and quantity
required.
For any further information on parts, service, or
ordering, consult your local dealer for Hyster lift trucks.

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2)

The first letter and three numbers indicate the truck unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number of the truck.

(5)

The final letter indicates the year of manufacture starting with "A" in 1957 and 1980.
The letters "I", "O", and "Q" will not be used.

For pending serial numbers contact your local dealer for Hyster lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

2004 HYSTER COMPANY

See Service Manual


for service procedures.

vii

UNIT CODE J160


EUROPE

02/2004

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

PUBLICATION

HYSTER PART NUMBER

Operating Manual .................................................................................................................. 1556470


Service Manual (Complete) .................................................................................................. 1554640
Parts Manual .......................................................................................................................... 1556469

viii

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

1 FRAME

FRAME

02/2004

UNIT CODE J160


EUROPE

SECTION 1
FRAME
DESCRIPTION

PAGE

BATTERY COMPARTMENT AND COVERS ........................................................................................................ 1-2


BATTERY SLIDER AND RETAINER .................................................................................................................... 1-6
COUNTERWEIGHT ............................................................................................................................................. 1-8
DECAL AND PLATE LOCATION ........................................................................................................................ 1-10
FLOOR PLATES................................................................................................................................................. 1-12
FORKS ............................................................................................................................................................... 1-14
LOAD BACKREST EXTENSION........................................................................................................................ 1-16
OVERHEAD GUARD.......................................................................................................................................... 1-18
SEAT................................................................................................................................................................... 1-20
STATIC STRAP................................................................................................................................................... 1-22

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1-1

UNIT CODE J160


EUROPE

02/2004

BATTERY COMPARTMENT AND COVERS (Figure 1-1)

1-2

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

BATTERY COMPARTMENT AND COVERS


QTY

ITEM

PART NO.

DESCRIPTION

1
2
3
4
5
6
6
6
7
7
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47

1528851
302048
320156
136687
1527262
1523615
1523614
1526650
1521321
1521405
1521406
369242
239503
320158
292681
1523623
292502
320156
292680
136687
362030
1530955
1533890
1536299
302231
221852
2037379
2307799
320161
182118
1528869
1541774
1541775
1541777
1541778
1527299
1527304
1525750
1525751
2310972
1553456
320158
292681
287851
269200
320159
292682
293629
15176
2311598
1527296

Cowl Cover ..................................................................................................................


Screw...........................................................................................................................
Washer ........................................................................................................................
Nut ...............................................................................................................................
Cover ...........................................................................................................................
Frame (1290 mm) ........................................................................................................
Frame (1385 mm) ........................................................................................................
Frame (1495 mm) ........................................................................................................
Battery Cover (1290 mm) ............................................................................................
Battery Cover (1385 mm) ............................................................................................
Battery Cover (1495 mm) ............................................................................................
Capscrew.....................................................................................................................
Nut ...............................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Backing Plate...............................................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Nut ...............................................................................................................................
Handle .........................................................................................................................
Latch Handle ...............................................................................................................
Microswitch ..................................................................................................................
Standoff .......................................................................................................................
Screw...........................................................................................................................
Lockwasher..................................................................................................................
Switch ..........................................................................................................................
Spring ..........................................................................................................................
Washer ........................................................................................................................
Retaining Ring .............................................................................................................
Pin ...............................................................................................................................
Seal Strip .....................................................................................................................
Seal Strip .....................................................................................................................
Seal Strip .....................................................................................................................
Seal Strip .....................................................................................................................
Bracket Weldment (RH) ...............................................................................................
Bracket Weldment (LH)................................................................................................
Bracket (RH) ................................................................................................................
Bracket (LH).................................................................................................................
Bearing ........................................................................................................................
Gas Spring...................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Capscrew.....................................................................................................................
Nut ...............................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Screw...........................................................................................................................
Short Arm ....................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
5
5
5
1
1
1
1
1
1
1
5
5
5
5
1
2
2
2
2
1
1
1
4
4
4
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
4
4
4
2
4
4
4
2
2
2
1-3

UNIT CODE J160


EUROPE

02/2004

BATTERY COMPARTMENT AND COVERS


ITEM

48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
65
65
65
65
66
67
68
69
70
71
72
73

PART NO.

182118
1527327
2056115
320161
1527326
1527297
1527304
1527330
320157
293613
292681
1527329
1527299
296252
1519095
1554624
1554625
1560099
1525348
1525349
a 1560101
b 1525351
1382311
1382312
1382313
1483422
320156
292680
136687
2062875

DESCRIPTION

QTY

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


Bracket Weldment (LH)................................................................................................
Bearing ........................................................................................................................
Washer ........................................................................................................................
Bracket Weldment (RH) ...............................................................................................
Long Arm .....................................................................................................................
Bracket Weldment (LH)................................................................................................
Bracket Weldment (LH)................................................................................................
Washer ........................................................................................................................
Capscrew.....................................................................................................................
Lockwasher..................................................................................................................
Bracket Weldment (RH) ...............................................................................................
Bracket Weldment (RH) ...............................................................................................
Bolt ..............................................................................................................................
Cowl.............................................................................................................................
Seal Strip .....................................................................................................................
Seal Strip .....................................................................................................................
Frame (1290 mm) ........................................................................................................
Frame (1385 mm) ........................................................................................................
Frame (1495 mm) ........................................................................................................
Frame (Optional)..........................................................................................................
Frame (Optional)..........................................................................................................
Panel............................................................................................................................
Panel............................................................................................................................
Cover ...........................................................................................................................
Horn.............................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Nut ...............................................................................................................................
Capscrew.....................................................................................................................

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

FOOTNOTES:
a 1290 mm - Side Removal
b 1385 mm - Side Removal

1-4

See Service Manual


for service procedures.

2004 HYSTER COMPANY

NOTES

1-5

UNIT CODE J160


EUROPE

02/2004

BATTERY SLIDER AND RETAINER (Figure 1-2)

1-6

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

BATTERY SLIDER AND RETAINER


ITEM

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

PART NO.

a 2014602
2014599
b 2014603
2014600
2307799
19890
2307965
167218
2309362
2307542
136692
292682
292519
1532511
296247
361973
320159
292682
136692
2053940
2053941

QTY

DESCRIPTION

Side Panel Assembly ...................................................................................................


Side Plate ....................................................................................................................
Side Panel Assembly ...................................................................................................
Side Plate ....................................................................................................................
Spring ..........................................................................................................................
Roll Pin ........................................................................................................................
Lock Pin .......................................................................................................................
Rod End Pin ................................................................................................................
Radial Bumper .............................................................................................................
Retainer .......................................................................................................................
Nut ...............................................................................................................................
Lockwasher..................................................................................................................
Capscrew.....................................................................................................................
Plate ............................................................................................................................
Screw...........................................................................................................................
Spacer .........................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Nut ...............................................................................................................................
Slide Platform (3,000 lb. Capacity Truck) ....................................................................
Slide Platform (3,500 lb. Capacity Truck) ....................................................................

1
1
1
1
2
2
2
2
2
2
2
2
2
1
2
10
2
2
2
1
1

FOOTNOTES:
a 1290 mm Wheel Base
b 1385 mm Wheel Base

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1-7

UNIT CODE J160


EUROPE

02/2004

COUNTERWEIGHT (Figure 1-3)

1-8

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

COUNTERWEIGHT
ITEM

1
2
3
4

QTY

PART NO.

DESCRIPTION

1529150
293706
296431
1527974

Counterweight .............................................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Tow Pin ........................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
4
4
1

1-9

UNIT CODE J160


EUROPE

02/2004

DECAL AND PLATE LOCATION (Figure 1-4)

1-10

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

DECAL AND PLATE LOCATION


ITEM

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

PART NO.

1339830
2049939
1339828
1538033
1538034
320037
1339672
1471618
a .. . . .
238950
170658
1343276
b 1339832
2303178
c 2304044
389688
15140
1385099
1544266
2068406
2068407
1366725
1359588
1538036
1538037
1529042
1339674
1560157
316448
1339832
2013578
2015059
2015060
1339667
1539387
2068404
2068405
1356137
370258
370259

QTY

DESCRIPTION

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


Label (Battery Disconnect) ..........................................................................................
Label (No Riders) ........................................................................................................
Label (Lift)....................................................................................................................
Label (Tilt)....................................................................................................................
Label (Patent Plate) .....................................................................................................
Label (Hyster) ..............................................................................................................
Label (Nameplate) .......................................................................................................
Nameplate ...................................................................................................................
Label (Incomplete Truck) .............................................................................................
Rivet.............................................................................................................................
Label (Mast Warning) ..................................................................................................
Label (Pinch Point) ......................................................................................................
Label (Tilt Column) ......................................................................................................
Label (Pinch Point) ......................................................................................................
Cover ...........................................................................................................................
Washer ........................................................................................................................
Label (Hydraulic Oil Fill)...............................................................................................
Label (Hyster) ..............................................................................................................
Label (Brake System Fluid) .........................................................................................
Label (Brake System Fluid) (Freezer)..........................................................................
Label (Operator Warning) ............................................................................................
Label (Operator Restraint) ...........................................................................................
Label (Sideshift)...........................................................................................................
Label (Auxiliary) ...........................................................................................................
Label (Hyster) ..............................................................................................................
Label (Hyster) (Optional) .............................................................................................
Label (Hyster) ..............................................................................................................
Label (Lifting Eye)........................................................................................................
Label (Pinch Point) ......................................................................................................
Strip .............................................................................................................................
Label (Model 1.60).......................................................................................................
Label (Model 1.80).......................................................................................................
Label (Model 2.00).......................................................................................................
Label (ACX) .................................................................................................................
Label (Brake System Fluid Tag)...................................................................................
Label (Brake System Fluid Tag) (Freezer) ...................................................................
Label (Lift and Tilt) .......................................................................................................
Label (Auxiliary Function - Side-Shift) .........................................................................
Label (Auxiliary Function - Fork Spreader) ..................................................................

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

FOOTNOTES:
a Contact your dealer
b Only uses 1 for Manual Hydraulics
c Only uses one for Manual Hydraulics

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1-11

UNIT CODE J160


EUROPE

02/2004

FLOOR PLATES (Figure 1-5)

1-12

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

FLOOR PLATES
KEY:
A: Electric Valve
B: Manual Valve
QTY
ITEM

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

PART NO.

2062267
2062264
2062266
2062265
2062560
2309317
1550531
1528551
1551236
1364542
2062718
2066709
a 2059533
a 2059534

DESCRIPTION

Floor Plate (LH) ...................................................................................................


Floor Plate (Center) .............................................................................................
Floor Plate (RH)...................................................................................................
Floor Plate (RH) (With Step)................................................................................
Anti-Slip Pad ........................................................................................................
Anti-Slip Pad ........................................................................................................
Hose Cover..........................................................................................................
Harness Cover.....................................................................................................
Harness Cover.....................................................................................................
Clip Nut ................................................................................................................
Capscrew.............................................................................................................
Capscrew.............................................................................................................
Floor Mat .............................................................................................................
Floor Mat .............................................................................................................

1
1
..
1
2
2
1
1
..
9
8
1
..
1

1
1
1
..
1
1
1
..
1
9
8
..
1
..

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1-13

UNIT CODE J160


EUROPE

02/2004

FORKS (Figure 1-6)

1-14

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

FORKS
ITEM

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

QTY

PART NO.

DESCRIPTION

1327021
1327022
1327023
1333043
1333044
1333045
1523732
1523733
1500782
302450
1378763
1378762
1378760

Fork (991 mm) (80 x 40 x 1000) ..................................................................................


Fork (1092 mm) (80 x 40 x 1100) ................................................................................
Fork (1194 mm) (80 x 40 x 1200) ................................................................................
Fork (991 mm) (100 x 40 x 1000) ................................................................................
Fork (1092 mm) (100 x 40 x 1100) ..............................................................................
Fork (1194 mm) (100 x 40 x 1200) ..............................................................................
Knob ............................................................................................................................
Pin ...............................................................................................................................
Spring ..........................................................................................................................
Pin ...............................................................................................................................
Latch ............................................................................................................................
Spring ..........................................................................................................................
Pin ...............................................................................................................................

2
2
2
2
2
2
1
1
1
1
1
1
1

1378765
a 1523734

Latch Kit (Includes Items 5-8) ......................................................................................


Retainer Pin .................................................................................................................

1
1

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1-15

UNIT CODE J160


EUROPE

02/2004

LOAD BACKREST EXTENSION (Figure 1-7)

1-16

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

LOAD BACKREST EXTENSION


ITEM

1
2
3
3
4
5

QTY

PART NO.

DESCRIPTION

1349446
1353533
221771
296423
292656
292683

Load Backrest Extension (965 mm).............................................................................


Capscrew.....................................................................................................................
Washer ........................................................................................................................
Washer (Optional)........................................................................................................
Nut ...............................................................................................................................
Lockwasher..................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
4
4
4
4
4

1-17

UNIT CODE J160


EUROPE

02/2004

OVERHEAD GUARD (Figure 1-8)

1-18

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

OVERHEAD GUARD
QTY

ITEM

PART NO.

DESCRIPTION

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

2034347
320162
216877
1343647
316678
1534632
1534633
1534634
1363916
1363917
2034348
1553963
1554932

Capscrew.....................................................................................................................
Washer ........................................................................................................................
Nut ...............................................................................................................................
Handle .........................................................................................................................
Screw...........................................................................................................................
Overhead Guard (1290 mm)........................................................................................
Overhead Guard (1385 mm)........................................................................................
Overhead Guard (1495 mm)........................................................................................
Plug .............................................................................................................................
Plug .............................................................................................................................
Capscrew.....................................................................................................................
Bushing........................................................................................................................
Bushing........................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

4
12
6
1
2
1
1
1
13
7
2
2
4

1-19

UNIT CODE J160


EUROPE

02/2004

SEAT (Figure 1-9)

1-20

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

SEAT
KEY:
A: Full Suspension (Vinyl with Arm)
B: Full Suspension (Cloth With Arm)
C: Non-Suspension
D: Full Suspension (Cloth)
E: Full Suspension (Vinyl)
A

ITEM

PART NO.

DESCRIPTION

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

1563192
1563193
1540035
1540036
1562666
1562665
1563207
1563351
1563209
1563218
1563212
1563230
1470152
1470153
1563222
1563350
1563353
320157
302400
392238
1563208
1563215
1563210
1563211
1467529
1483828
1563231
1389343
287831

Seat (Vinyl) (Standard) .......................................................


Seat (Cloth) (Option) ..........................................................
Seat (Option) ......................................................................
Seat (Option) ......................................................................
Seat (Option) ......................................................................
Seat (Option) ......................................................................
Seat Cushion ......................................................................
Cushion ..............................................................................
Slide....................................................................................
Slide....................................................................................
Seat Belt .............................................................................
Arm (LH) .............................................................................
Back Cushion (Vinyl) ..........................................................
Back Cushion (Fabric) ........................................................
Cushion ..............................................................................
Harness ..............................................................................
Harness ..............................................................................
Washer ...............................................................................
Locknut ...............................................................................
Grommet.............................................................................
Sensor ................................................................................
Sensor ................................................................................
Foam Cap ...........................................................................
Knob ...................................................................................
Suspension Spring Kit ........................................................
Shock Absorber ..................................................................
Arm (RH) ............................................................................
Spacer ................................................................................
Capscrew............................................................................

a
a
a
a
a
a
a
a
a

..
..
1
..
..
..
1
..
1
..
1
1
1
..
..
1
..
4
4
1
1
..
1
1
1
1
..
..
..

QTY
C

..
..
..
1
..
..
1
..
1
..
1
1
..
1
..
1
..
4
4
1
1
..
1
1
1
1
..
..
..

1
1
..
..
..
..
..
1
..
1
1
..
..
..
1
..
1
4
4
1
..
1
..
..
..
..
..
2
4

..
..
..
..
1
..
1
..
1
..
1
1
..
1
..
..
1
4
4
1
1
..
..
..
1
1
1
..
..

..
..
..
..
..
1
1
..
1
..
1
1
1
..
..
..
1
4
4
1
1
..
..
..
1
1
1
..
..

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1-21

UNIT CODE J160


EUROPE

02/2004

STATIC STRAP (Figure 1-10)

1-22

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

STATIC STRAP
ITEM

1
2
3
4
5
6
7
8
9

QTY

PART NO.

DESCRIPTION

.. . . .
302977
216895
287860
320160
320159
292682
136692
.. . . .

Drive Tire and Wheel Assembly ( Figure 3-1) ........................................................


Nut ...............................................................................................................................
Static Strap ..................................................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Nut ...............................................................................................................................
Steer Tire and Wheel Assembly ( Figure 4-7) ........................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

2
5
1
1
1
1
1
1
2

1-23

NOTES

1-24

UNIT CODE J160


EUROPE

02/2004

2 ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

02/2004

UNIT CODE J160


EUROPE

SECTION 2
ELECTRICAL SYSTEM
DESCRIPTION

PAGE

BATTERY CONNECTOR
DIN.................................................................................................................................................................... 2-2
NON-DIN........................................................................................................................................................... 2-4
CONTACTOR PANEL ........................................................................................................................................... 2-6
DASH DISPLAY.................................................................................................................................................... 2-8
ELECTRO-HYDRAULIC CONTROL ................................................................................................................. 2-10
EMERGENCY STOP.......................................................................................................................................... 2-12
MAIN WIRE HARNESS...................................................................................................................................... 2-14
TRACTION CONTROLLER
CONTACTOR HYDRAULIC ............................................................................................................................ 2-18
TRANSISTOR/PREMIUM ............................................................................................................................... 2-20

2004 HYSTER COMPANY

See Service Manual


for service procedures.

2-1

UNIT CODE J160


EUROPE

02/2004

BATTERY CONNECTOR (Figure 2-1)


DIN

2-2

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

BATTERY CONNECTOR
DIN
ITEM

1
1
1
1
2
3
4
5
6
7

QTY

PART NO.

DESCRIPTION

1541453
2031026
190811
2308995
302054
292680
136687
1564043
292681
136681

Battery Connector (48V)..............................................................................................


1
Connector................................................................................................................
1
Cable ....................................................................................................................... AR
Terminal...................................................................................................................
2
Screw...........................................................................................................................
4
Lockwasher..................................................................................................................
4
Nut ...............................................................................................................................
4
Plate ............................................................................................................................
1
Lockwasher..................................................................................................................
2
Capscrew.....................................................................................................................
2

2004 HYSTER COMPANY

See Service Manual


for service procedures.

2-3

UNIT CODE J160


EUROPE

02/2004

BATTERY CONNECTOR (Figure 2-2)


NON-DIN

2-4

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

BATTERY CONNECTOR
NON-DIN
ITEM

1
1
1
1
2
3
4
5
6
7

QTY

PART NO.

DESCRIPTION

1541451
378383
190811
2308995
302053
292680
136687
1564043
292681
136681

Battery Connector (48V)..............................................................................................


1
Connector................................................................................................................
1
Cable ....................................................................................................................... AR
Terminal...................................................................................................................
2
Screw...........................................................................................................................
4
Lockwasher..................................................................................................................
4
Nut ...............................................................................................................................
4
Plate ............................................................................................................................
1
Lockwasher..................................................................................................................
2
Capscrew.....................................................................................................................
2

2004 HYSTER COMPANY

See Service Manual


for service procedures.

2-5

UNIT CODE J160


EUROPE

02/2004

CONTACTOR PANEL (Figure 2-3)

2-6

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

CONTACTOR PANEL
KEY:
A: Contactor Hydraulics
B: Transistor/Premium Hydraulics
QTY
ITEM

PART NO.

DESCRIPTION

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

1529243
1529244
1500263
1562874
1456085
2302461
1356209
2307803
2303821
2304170
1545108
383977
1562878
2034484
2035396
1562879
383981
383979
1500360
2034488
2307031
1454478
1547627
1545111
302020
2305577
1356204
292680
292500
325810
380689
1374793

Contactor Panel ...................................................................................................


1
Contactor Panel ...................................................................................................
..
Fuse (5 Amp)...................................................................................................
3
Fuse (20 Amp).................................................................................................
1
Fuse Holder.....................................................................................................
1
Screw ..............................................................................................................
2
Lockwasher .....................................................................................................
2
Washer ............................................................................................................
2
Screw ..............................................................................................................
2
Washer ............................................................................................................
2
Contactor.........................................................................................................
1
Screw ..........................................................................................................
2
Cover...........................................................................................................
1
Contactor (Fixed) ........................................................................................
2
Contactor (Moving) .....................................................................................
1
Return Spring..............................................................................................
1
Base............................................................................................................
1
Plunger........................................................................................................
1
Coil and Frame............................................................................................
1
End Cap ......................................................................................................
1
Buss Bar..........................................................................................................
1
Terminal Post...................................................................................................
5
Baseplate ........................................................................................................
1
Washer ............................................................................................................ 10
Screw .............................................................................................................. 10
Nut...................................................................................................................
5
Lockwasher .....................................................................................................
5
Lockwasher..........................................................................................................
4
Capscrew.............................................................................................................
4
Fuse (500 Amp) ...................................................................................................
1
Fuse (60 Amp) .....................................................................................................
1
Fuse (10 Amp) .....................................................................................................
1

2004 HYSTER COMPANY

See Service Manual


for service procedures.

..
1
3
1
1
2
2
2
2
2
1
2
1
2
1
1
1
1
1
1
..
3
1
6
6
3
3
4
4
..
1
1

2-7

UNIT CODE J160


EUROPE

02/2004

DASH DISPLAY (Figure 2-4)

2-8

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

DASH DISPLAY
ITEM

1
1
1
1

QTY

PART NO.

DESCRIPTION

1525767
1538447
1542513
1542514

Dash Display (Premium)..............................................................................................


Dash Display (Standard)..............................................................................................
Dash Display (Standard Freezer) ................................................................................
Dash Display (Premium Freezer).................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
1
1
1

2-9

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC CONTROL (Figure 2-5)

2-10

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC CONTROL
KEY:
A: Three Function Premium
B: Three Function Premium with Interlock
C: Four Function Premium
D: Four Function Premium with Interlock
QTY
ITEM

1
2
3
4
5
5
6

PART NO.

DESCRIPTION

1525760
292679
2056600
2066709
2068817
2068818
2062743

Valve Controller .............................................................................


Lockwasher....................................................................................
Nut .................................................................................................
Capscrew.......................................................................................
Wire Harness.................................................................................
Wire Harness.................................................................................
Jumper Assembly ..........................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
2
2
2
1
..
1

1
2
2
2
1
..
1

1
2
2
2
..
1
1

1
2
2
2
..
1
1

2-11

UNIT CODE J160


EUROPE

02/2004

EMERGENCY STOP (Figure 2-6)

2-12

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

EMERGENCY STOP
QTY

ITEM

PART NO.

DESCRIPTION

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

1540616
1545115
1545117
1545118
1545120
1545121
1545122
1545123
1545124
1545125
1545126
1545127
1545128
1545129
1545130
1545131
1545132
1545133
1545134
1547685
2304572

Emergency Stop Switch ("E") ......................................................................................


Top Cover Assembly................................................................................................
Screw ......................................................................................................................
Circup ......................................................................................................................
Insulator (Black) ......................................................................................................
Spring (Contact) ......................................................................................................
Contact Kit...............................................................................................................
Washer ....................................................................................................................
Dust Shield ..............................................................................................................
Housing ...................................................................................................................
Spring (Actuator) .....................................................................................................
Shaft ........................................................................................................................
O-Ring .....................................................................................................................
Guide.......................................................................................................................
Backplate.................................................................................................................
Gasket .....................................................................................................................
Hardware Kit............................................................................................................
Auxiliary Contact Kit ................................................................................................
Insulator (White) ......................................................................................................
Bushing ...................................................................................................................
Washer ....................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
1
2
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
2
2

2-13

UNIT CODE J160


EUROPE

02/2004

MAIN WIRE HARNESS (Figure 2-7)

2-14

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MAIN WIRE HARNESS


QTY

ITEM

PART NO.

DESCRIPTION

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

2056352
1484397
1463194
1330438
1306270
1310142
2308915
381413
2044992
2044998
2068741
2035275
2035276
2068741
2056244
2035276
2060666
2307413
381413
2047820
2047819
2305754
2066313
2308915
381413
2044992
2044998
1493465
1330414
1330437
1490242
1490243
1330438
1490242
1490243
1330438
1484397
1532664
1330438
1351682
1484397
1463194
1330438
1493430
1529052
1330438
1330434
1493430
1529052
1330438
1330434

Wire Harness...............................................................................................................
Housing (Socket) .....................................................................................................
Secondary Lock.......................................................................................................
Socket .....................................................................................................................
Electrical Fitting .......................................................................................................
Blade .......................................................................................................................
Plug .........................................................................................................................
Socket .....................................................................................................................
Interface Seal ..........................................................................................................
Amp Wire Seal ........................................................................................................
Plug .........................................................................................................................
Connector................................................................................................................
Socket .....................................................................................................................
Plug .........................................................................................................................
Electrical Connector ................................................................................................
Socket .....................................................................................................................
Resistor ...................................................................................................................
Connector................................................................................................................
Socket .....................................................................................................................
Wire Seal.................................................................................................................
Amp Interface Seal..................................................................................................
Terminal...................................................................................................................
Diode Assembly ......................................................................................................
Plug .........................................................................................................................
Socket .....................................................................................................................
Interface Seal ..........................................................................................................
Amp Wire Seal ........................................................................................................
Connector................................................................................................................
Secondary Lock.......................................................................................................
Pin ...........................................................................................................................
Housing (Socket) .....................................................................................................
Secondary Lock.......................................................................................................
Socket .....................................................................................................................
Housing (Socket) .....................................................................................................
Secondary Lock.......................................................................................................
Socket .....................................................................................................................
Housing (Socket) .....................................................................................................
Secondary Lock.......................................................................................................
Socket .....................................................................................................................
End Cap ..................................................................................................................
Housing (Socket) .....................................................................................................
Secondary Lock.......................................................................................................
Socket .....................................................................................................................
Housing ...................................................................................................................
Secondary Lock.......................................................................................................
Socket .....................................................................................................................
Terminal...................................................................................................................
Housing ...................................................................................................................
Secondary Lock.......................................................................................................
Socket .....................................................................................................................
Terminal...................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
1
1
3
2
2
1
3
1
1
6
1
17
8
1
6
1
1
2
1
1
1
1
1
3
1
1
1
1
2
1
1
2
2
2
4
1
1
3
1
1
1
3
1
1
2
4
1
1
2
4
2-15

UNIT CODE J160


EUROPE

02/2004

MAIN WIRE HARNESS


ITEM

PART NO.

19
20
21
22
22
23
24
25
25
25
26
26
26
27
27
27
27
28
28
28
28
29
30
30
30
31
31
31
32
32
32
32
33
34
35
36
37
38
39
40
40
40
41
41
41
42
43
43
43
44
45
46

1351681
2062873
2007554
248196
222523
1306270
1306271
2308118
1305672
2047820
1484397
1463194
1330438
2308915
381413
2044992
2044998
2307413
381413
2047820
2047819
2043953
1369412
2069412
1305672
1490242
1490243
1330438
2037543
2044997
2045003
381413
1547602
2068745
2062871
2303345
1369410
2069413
2305754
2068741
2056243
2035276
2068741
2069414
2035276
2311380
2068741
2056244
2035276
2060666
2305754
2307413

2-16

DESCRIPTION

QTY

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


1
Electrical Fitting .......................................................................................................
2
Terminal...................................................................................................................
1
Fitting.......................................................................................................................
1
Heat Shrink Tube.....................................................................................................
1
Electrical Fitting .......................................................................................................
2
Electrical Fitting .......................................................................................................
1
Connector................................................................................................................
2
Pin ...........................................................................................................................
4
Wire Seal.................................................................................................................
2
Housing (Socket) .....................................................................................................
1
Secondary Lock.......................................................................................................
1
Socket .....................................................................................................................
3
Plug .........................................................................................................................
2
Socket .....................................................................................................................
6
Interface Seal ..........................................................................................................
2
Amp Wire Seal ........................................................................................................
2
Connector................................................................................................................
1
Socket .....................................................................................................................
2
Wire Seal.................................................................................................................
1
Amp Interface Seal ..................................................................................................
1
Terminal Ring ..........................................................................................................
1
Cap..........................................................................................................................
1
Wire Seal.................................................................................................................
1
Pin ........................................................................................................................... 12
Housing (Socket) .....................................................................................................
1
Secondary Lock.......................................................................................................
1
Socket .....................................................................................................................
2
Plug .........................................................................................................................
1
Connector................................................................................................................
1
Connector................................................................................................................
1
Socket .....................................................................................................................
4
Wire Harness ..........................................................................................................
1
Tube......................................................................................................................... AR
Terminal Wire ..........................................................................................................
1
Terminal (Ring) ........................................................................................................
5
Terminal Wire ..........................................................................................................
4
Terminal Ring ..........................................................................................................
1
Terminal...................................................................................................................
2
Plug .........................................................................................................................
1
Connector................................................................................................................
1
Socket ..................................................................................................................... 34
Plug .........................................................................................................................
4
Connector and Cable Assembly ..............................................................................
1
Socket .....................................................................................................................
4
Terminal Wire ..........................................................................................................
1
Plug .........................................................................................................................
7
Electrical Connector ................................................................................................
1
Socket .....................................................................................................................
7
Resistor ...................................................................................................................
1
Terminal...................................................................................................................
2
Connector................................................................................................................
1
See Service Manual
for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MAIN WIRE HARNESS


ITEM

PART NO.

46
46
46
47
47
47
48
49
50
50
50
50
50
51
51
52
53
54

381413
2047820
2047819
1541991
1541992
1463139
2037545
2034482
1493430
1529052
1330438
1363886
1351683
2037544
2309579
2069415
1310142
2049309

2004 HYSTER COMPANY

DESCRIPTION

QTY

Socket .....................................................................................................................
2
Wire Seal.................................................................................................................
1
Amp Interface Seal..................................................................................................
1
Connector................................................................................................................
1
Connector................................................................................................................
1
Terminal...................................................................................................................
8
Terminal...................................................................................................................
4
Tubing...................................................................................................................... AR
Housing ...................................................................................................................
1
Secondary Lock.......................................................................................................
1
Socket .....................................................................................................................
4
Socket .....................................................................................................................
2
Connector................................................................................................................
1
Connector................................................................................................................
1
Socket (Molex).........................................................................................................
3
Terminal Wire ..........................................................................................................
1
Blade .......................................................................................................................
1
Wire Terminal ..........................................................................................................
1

See Service Manual


for service procedures.

2-17

UNIT CODE J160


EUROPE

02/2004

TRACTION CONTROLLER (Figure 2-8)


CONTACTOR HYDRAULIC

2-18

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

TRACTION CONTROLLER
CONTACTOR HYDRAULIC
KEY:
A: 1290 mm/1385 mm Wheel Base
B: 1495 mm Wheel Base
QTY
ITEM

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

PART NO.

2055624
1539327
1555987
320156
292680
293799
2062006
2062360
2062005
2056878
2062351
2056880
2062361
2056852
2062350
2062022
2062023
1564241
2062024
2062025
320156
292680
292500
a 2060507

DESCRIPTION

Traction Controller................................................................................................
Software ..........................................................................................................
Contactor .............................................................................................................
Washer ................................................................................................................
Lockwasher..........................................................................................................
Capscrew.............................................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable ........................................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Ferrite ..................................................................................................................
Power Cable ........................................................................................................
Power Cable ........................................................................................................
Washer ................................................................................................................
Lockwasher..........................................................................................................
Capscrew.............................................................................................................
Wire Harness.......................................................................................................

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

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

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

2-19

UNIT CODE J160


EUROPE

02/2004

TRACTION CONTROLLER (Figure 2-9)


TRANSISTOR/PREMIUM

2-20

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

TRACTION CONTROLLER
TRANSISTOR/PREMIUM
KEY:
A: 1290 mm/1385 mm Wheel Base
B: 1495 mm Wheel Base
QTY
ITEM

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

PART NO.

DESCRIPTION

2055625
1539328
320156
292680
293799
2062009
2062006
2062360
2056878
2062351
2056880
2062361
2056852
2062350
2062022
2062023
1564241
1564205
2062024
2062025
320156
292680
292500
2060510
2060511
2068817
2068818

Traction Controller................................................................................................
Software ..........................................................................................................
Washer ................................................................................................................
Lockwasher..........................................................................................................
Capscrew.............................................................................................................
Power Cable ........................................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Power Cable Assembly ........................................................................................
Ferrite ..................................................................................................................
Capacitor .............................................................................................................
Power Cable ........................................................................................................
Power Cable ........................................................................................................
Washer ................................................................................................................
Lockwasher..........................................................................................................
Capscrew.............................................................................................................
Wire Harness.......................................................................................................
Wire Harness.......................................................................................................
Wire Harness (Three Function) ...........................................................................
Wire Harness (Four Function) .............................................................................

1
1
8
8
8
1
1
..
1
..
1
..
1
..
1
1
5
1
1
1
2
2
2
1
1
1
1

1
1
8
8
8
1
..
1
..
1
..
1
..
1
1
1
5
1
1
1
2
2
2
1
1
1
1

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

2-21

NOTES

2-22

UNIT CODE J160


EUROPE

02/2004

3 D RIVE UNIT

DRIVE UNIT

02/2004

UNIT CODE J160


EUROPE

SECTION 3
DRIVE UNIT
DESCRIPTION

PAGE

DRIVE TIRE AND WHEEL ASSEMBLY


SOLID PNEUMATIC .........................................................................................................................................
DRIVE UNIT .........................................................................................................................................................
TRACTION MOTOR .............................................................................................................................................
TRANSMISSION ..................................................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

3-2
3-4
3-6
3-8

3-1

UNIT CODE J160


EUROPE

02/2004

DRIVE TIRE AND WHEEL ASSEMBLY (Figure 3-1)


SOLID PNEUMATIC

KEY:
A: 3000-3500 lbs.
B: 4000 lbs.
QTY
ITEM

1
1
2
2
3

3-2

PART NO.

DESCRIPTION

1539497
1539490
2035601
2035605
2036125
2036126
302977

Tire and Wheel Assembly....................................................................................


Tire and Wheel Assembly....................................................................................
Tire (18 x 7 x 8) ...................................................................................................
Tire (200 x 50 x 10) .............................................................................................
Wheel (18 x 7 x 8) ...............................................................................................
Wheel (200 x 50 x 10) .........................................................................................
Nut .......................................................................................................................

See Service Manual


for service procedures.

2
..
1
..
1
..
5

..
2
..
1
..
1
5

2004 HYSTER COMPANY

NOTES

3-3

UNIT CODE J160


EUROPE

02/2004

DRIVE UNIT (Figure 3-2)

3-4

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

DRIVE UNIT
ITEM

1
2
3
4
5
ab
ab
ac
ac

QTY

PART NO.

DESCRIPTION

2061746
2061747
2063091
296420
293630
2056878
2056852
2062351
2062350

Drive Unit (LH) ( Figure 3-4) ...................................................................................


Drive Unit (RH) ( Figure 3-4) ..................................................................................
Traction Motor (48V) ( Figure 3-3) ..........................................................................
Washer ........................................................................................................................
Capscrew.....................................................................................................................
Power Cable Assembly (LH) ........................................................................................
Power Cable Assembly (RH) .......................................................................................
Power Cable Assembly (LH) ........................................................................................
Power Cable Assembly (RH) .......................................................................................

1
1
2
8
8
1
1
1
1

FOOTNOTES:
a Not Illustrated
b Used on 1290 and 1385 mm
c Used on 1495 mm

2004 HYSTER COMPANY

See Service Manual


for service procedures.

3-5

UNIT CODE J160


EUROPE

02/2004

TRACTION MOTOR (Figure 3-3)

3-6

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

TRACTION MOTOR
ITEM

1
2
3
4
5
6
7

QTY

PART NO.

DESCRIPTION

2063091
1564559
1564560
1564561
1564562
1564592
1564593
1564594

Traction Motor ( Figure 3-2) ....................................................................................


Drive End Bracket....................................................................................................
Armature .................................................................................................................
Bolt ..........................................................................................................................
Stator.......................................................................................................................
Connection Plate .....................................................................................................
Bracket ....................................................................................................................
Connector................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
1
1
1
1
1
1
1

3-7

UNIT CODE J160


EUROPE

02/2004

TRANSMISSION (Figure 3-4)

3-8

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

TRANSMISSION
KEY:
A: Left
B: Right
QTY
ITEM

PART NO.

DESCRIPTION

1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
42

2061746
2061747
1561561
1557381
1557382
1557393
1557396
1497282
1497280
1557394
1557395
1557397
1557398
1557399
1557400
1557404
1557405
1557406
1557407
1557435
1557441
1557442
1557443
1533937
1557444
1557445
1557446
1557447
1557448
1557449
1557450
1557451
1557452
1557454
1557455
1557467
1557470
1557471
1557472
1557474
1557475
1557480
1557392
1557383
1557401
1557402

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


1
Drive Unit (Right) ( Figure 3-2) .......................................................................
..
Housing Assembly (Left) .................................................................................
1
Housing Assembly (Right)...............................................................................
..
Pin...............................................................................................................
1
Bolt..............................................................................................................
4
Bolt..............................................................................................................
8
Oil Fill Gasket ..................................................................................................
2
Oil Fill Plug ......................................................................................................
2
Plug .................................................................................................................
2
Pin ...................................................................................................................
2
Plug .................................................................................................................
1
Washer ............................................................................................................
1
Bearing ............................................................................................................
3
Gear Assembly................................................................................................
1
O-Ring .............................................................................................................
2
Spacer .............................................................................................................
2
Snap Ring........................................................................................................
2
Seal Ring.........................................................................................................
1
Bolt ..................................................................................................................
1
O-Ring .............................................................................................................
1
Washer ............................................................................................................
1
Output Shaft ....................................................................................................
1
Bolt ..................................................................................................................
5
Seal Ring.........................................................................................................
1
Bearing ............................................................................................................
2
Carrier .............................................................................................................
1
Washer ............................................................................................................
2
Ring .................................................................................................................
3
Bearing ............................................................................................................
3
Gear ................................................................................................................
3
Snap Ring........................................................................................................
3
Bearing ............................................................................................................
1
Gear ................................................................................................................
1
Pinion ..............................................................................................................
1
Plug .................................................................................................................
1
Piston ..............................................................................................................
2
O-Ring .............................................................................................................
2
Pin ...................................................................................................................
2
Washer ............................................................................................................ 24
Backing Plate ..................................................................................................
1
Brake Assembly...............................................................................................
1
Breather...........................................................................................................
1
Breather...........................................................................................................
1
Shim (0,05 mm)............................................................................................... AR
Shim (0,10 mm)............................................................................................... AR

2004 HYSTER COMPANY

See Service Manual


for service procedures.

..
1
..
1
1
4
8
2
2
2
2
1
1
3
1
2
2
2
1
1
1
1
1
5
1
2
1
2
3
3
3
3
1
1
1
1
2
2
2
24
1
1
1
1
..
..
3-9

UNIT CODE J160


EUROPE

02/2004

TRANSMISSION

ITEM

42
43
44
44
44
44
45
46

PART NO.

1557403
1557436
1557437
1557438
1557439
1557440
296426
293685
a 302977

DESCRIPTION

Shim (0,30 mm)...............................................................................................


Washer ............................................................................................................
Shim (0,05 mm)...............................................................................................
Shim (0,10 mm)...............................................................................................
Shim (0,30 mm)...............................................................................................
Shim (0,50 mm)...............................................................................................
Washer (Hardened) .............................................................................................
Capscrew.............................................................................................................
Nut .......................................................................................................................

AR
1
AR
AR
AR
AR
5
5
5

QTY
B

..
1
..
..
..
..
5
5
5

FOOTNOTES:
a Not Illustrated

3-10

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

4 STEERING SYSTEM

STEERING SYSTEM

02/2004

UNIT CODE J160


EUROPE

SECTION 4
STEERING SYSTEM
DESCRIPTION

PAGE

GEAR PUMP ........................................................................................................................................................ 4-2


HAND PUMP ........................................................................................................................................................ 4-4
SHIFT LEVER ...................................................................................................................................................... 4-6
STEER AXLE ....................................................................................................................................................... 4-8
STEER COLUMN ............................................................................................................................................... 4-12
STEER PUMP AND MOTOR ............................................................................................................................. 4-16
STEER TIRE AND WHEEL ASSEMBLY
SOLID PNEUMATIC ....................................................................................................................................... 4-18

2004 HYSTER COMPANY

See Service Manual


for service procedures.

4-1

UNIT CODE J160


EUROPE

02/2004

GEAR PUMP (Figure 4-1)

4-2

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

GEAR PUMP
ITEM

1
2
3
4
5
6
7
8
9
10
11

PART NO.

2033614
1452459
2034266
354669
358072
358069
.. . . .
2034265
354671
358076
358073
1309877
a 1322446
a 1322447
a 1322448

QTY

DESCRIPTION

Gear Pump ..................................................................................................................


Screw ......................................................................................................................
Gasket Kit................................................................................................................
Needle Bearing .......................................................................................................
Snap Ring................................................................................................................
Gear ........................................................................................................................
Spacer Plate .......................................................................................................
Idler Shaft Kit...........................................................................................................
Pin ...........................................................................................................................
Plug .........................................................................................................................
Key ..........................................................................................................................
Shaft ........................................................................................................................
Plug (Plastic) ...........................................................................................................
Plug (Plastic) ...........................................................................................................
Plug (Steel)..............................................................................................................

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

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

4-3

UNIT CODE J160


EUROPE

02/2004

HAND PUMP (Figure 4-2)

4-4

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HAND PUMP
QTY

ITEM

PART NO.

DESCRIPTION

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

1462468
1467390
.. . . .
1355335
1451696
.. . . .
1467424
1451697
1455770
1451698
1455771
.. . . .
1467426
.. . . .
1451703
1467391
.. . . .
1455773
.. . . .
1467425
1467392
1467428
.. . . .
1455776
1455779
1451707

Hand Pump..................................................................................................................
Dust Seal.................................................................................................................
Housing ...................................................................................................................
Ball ..........................................................................................................................
Stop .........................................................................................................................
Dust Ring Seal ........................................................................................................
Shaft Seal................................................................................................................
Bearing Assembly ...................................................................................................
Ring .........................................................................................................................
Pin ...........................................................................................................................
Spring Set ...............................................................................................................
Shaft ........................................................................................................................
Spacer .....................................................................................................................
O-Ring .....................................................................................................................
Plate ........................................................................................................................
Gear Set ..................................................................................................................
O-Ring .....................................................................................................................
Cover .......................................................................................................................
O-Ring .....................................................................................................................
O-Ring .....................................................................................................................
Screw ......................................................................................................................
Screw ......................................................................................................................
Nameplate ...................................................................................................................
Relief Valve..................................................................................................................
Spring ..........................................................................................................................
Ball...............................................................................................................................

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
5
1
1
4
1
1
1
1

1467430

Seal Kit (Includes Items 1, 5, 12, 15, 17).....................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

4-5

UNIT CODE J160


EUROPE

02/2004

SHIFT LEVER (Figure 4-3)

4-6

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

SHIFT LEVER
QTY

ITEM

PART NO.

DESCRIPTION

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

1347004
1343594
1343578
1354300
1343579
1343598
136687
302398
1343593
296205
1343577
1491830
320156
292680
292501
1343595
1498406
220426
53162
16865

Shift Lever Assembly ...................................................................................................


Bolt ..........................................................................................................................
Link..........................................................................................................................
Washer ....................................................................................................................
Crank.......................................................................................................................
Crank.......................................................................................................................
Nut...........................................................................................................................
Locknut....................................................................................................................
Shift Lever ...............................................................................................................
Capscrew ................................................................................................................
Base ........................................................................................................................
Spring Plunger ........................................................................................................
Washer ....................................................................................................................
Lockwasher .............................................................................................................
Capscrew ................................................................................................................
Plate ........................................................................................................................
Switch......................................................................................................................
Screw ......................................................................................................................
Lockwasher .............................................................................................................
Nut...........................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

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

4-7

UNIT CODE J160


EUROPE

02/2004

STEER AXLE (Figure 4-4)

4-8

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

STEER AXLE
QTY

ITEM

PART NO.

DESCRIPTION

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
20
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
37
38
39
40
41
42
43
44
45
46
46

1494373
1465784
1495390
1465787
1495391
1465792
1465793
1465794
1465795
1465796
1465797
1465800
1465801
1465813
1465814
1495395
1465817
1465818
1465819
1465820
1465821
1465822
1495394
1495392
1465824
1465823
1465825
1465826
1465827
1465828
1465829
1471650
1495397
1495398
1495399
1465834
1462527
296426
1462528
1495389
1495388
2034281
2004005
292507
1339396
1508484
136687
1528189
2056352
1521399
1521400

Hydraulic Steer Unit.....................................................................................................


1
Housing ...................................................................................................................
1
Wheel Hub...............................................................................................................
2
Cylinder ...................................................................................................................
2
Bushing ...................................................................................................................
2
Piston ......................................................................................................................
2
Shaft ........................................................................................................................
1
Gear Rack ...............................................................................................................
1
Wheel Stud.............................................................................................................. 10
Bushing ...................................................................................................................
1
Bearing Cover .........................................................................................................
2
Bearing ....................................................................................................................
2
Bearing ....................................................................................................................
2
Bearing ....................................................................................................................
1
Bearing ....................................................................................................................
1
Seal Ring.................................................................................................................
2
Seal .........................................................................................................................
1
Seal .........................................................................................................................
1
Safety Ring..............................................................................................................
1
Shim ........................................................................................................................
1
Shim ........................................................................................................................
2
Shim ........................................................................................................................
1
Shim ........................................................................................................................
1
Ring .........................................................................................................................
2
Shaft Seal................................................................................................................
1
Shaft Seal................................................................................................................
1
O-Ring .....................................................................................................................
2
Compact Seal..........................................................................................................
2
Guide Ring ..............................................................................................................
4
Nut...........................................................................................................................
1
Washer ....................................................................................................................
1
Screw ......................................................................................................................
8
Nut...........................................................................................................................
2
Seal .........................................................................................................................
2
Split Pin ...................................................................................................................
2
Plug Screw ..............................................................................................................
1
Bolt ..........................................................................................................................
3
Washer (Hardened) .................................................................................................
6
Nut...........................................................................................................................
3
Yoke.........................................................................................................................
1
Wheel Shaft.............................................................................................................
1
Potentiometer ..............................................................................................................
1
Strap Clamp................................................................................................................. AR
Capscrew.....................................................................................................................
1
Bracket.........................................................................................................................
1
Set Screw ....................................................................................................................
1
Nut ...............................................................................................................................
1
Fitting...........................................................................................................................
1
Wire Harness (Main)....................................................................................................
1
Hose Assembly (2642 mm) .........................................................................................
1
Hose Assembly (2743 mm) .........................................................................................
1

2004 HYSTER COMPANY

See Service Manual


for service procedures.

4-9

UNIT CODE J160


EUROPE

02/2004

STEER AXLE
ITEM

PART NO.

DESCRIPTION

46
47
48
48
48

1521401
222399
1521402
1521403
1521404
259665
1495393
1471658
1495400

Hose Assembly (2845 mm) .........................................................................................


Fitting ...........................................................................................................................
Hose Assembly (2820 mm) .........................................................................................
Hose Assembly (2921 mm) .........................................................................................
Hose Assembly (3023 mm) .........................................................................................
Guard...........................................................................................................................
Nameplate ...................................................................................................................
Pin ...............................................................................................................................
Plastic Cover................................................................................................................

1
2
1
1
1
7
1
2
2

1497558
1475400
1475399

Axle Seal Kit (Includes Items 15, 21) ......................................................................


Axle Seal Kit (Includes Items 9, 16-17, 22-23, 33)..............................................
Cylinder Seal Kit (Includes Items 24-26).............................................................

1
1
1

a
a
a
a

QTY

FOOTNOTES:
a Not Illustrated

4-10

See Service Manual


for service procedures.

2004 HYSTER COMPANY

NOTES

4-11

UNIT CODE J160


EUROPE

02/2004

STEER COLUMN (Figure 4-5)

4-12

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

STEER COLUMN
ITEM

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

b
c

a
a
a
a
a
a

QTY

PART NO.

DESCRIPTION

1520733
1520731
1343573
2045129
1364271
1462468
15134
15156
16815
293779
293762
1343607
15212
1335987
1378600
1335967
292681
136749
1343572
320155
1343537
1347004
1329250
1539289
1520270
2306145
166857
1520609
379902
1337196
1520271
1343574
296472
1376743
1343597
895468
1450503
1539290
320156
292680
292501
1510874
1530681
1528191
1347314
136985
320159
292682

Steer Column (Monotrol) .............................................................................................


Steer Column (With Levers) ........................................................................................
Bracket ....................................................................................................................
Steering Column .....................................................................................................
Latch........................................................................................................................
Hand Pump ( Figure 4-2) ...................................................................................
Washer ....................................................................................................................
Lockwasher .............................................................................................................
Capscrew ................................................................................................................
Lockwasher .............................................................................................................
Capscrew ................................................................................................................
Pin ...........................................................................................................................
Cotter Pin ................................................................................................................
Shaft ........................................................................................................................
Spring ......................................................................................................................
Plate ........................................................................................................................
Lockwasher .............................................................................................................
Capscrew ................................................................................................................
Rod..........................................................................................................................
Washer ....................................................................................................................
Spring ......................................................................................................................
Shift Lever Assembly (With Levers) ( Figure 4-3) ...............................................
Steering Wheel (356 mm)............................................................................................
Steering Wheel (305 mm)............................................................................................
Cover (Upper) ..............................................................................................................
Tube .............................................................................................................................
Clamp ..........................................................................................................................
Static Ground Patch.....................................................................................................
Ignition Switch .............................................................................................................
Screw...........................................................................................................................
Cover (Lower) ..............................................................................................................
Latch Knob ..................................................................................................................
Screw...........................................................................................................................
Plug .............................................................................................................................
Plug .............................................................................................................................
Knob ............................................................................................................................
Horn Button .................................................................................................................
Horn Button .................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Capscrew.....................................................................................................................
Wire Harness...............................................................................................................
Hose (2540 mm) ..........................................................................................................
Hose (1270 mm) ..........................................................................................................
Insulated Clamp...........................................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

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

4-13

UNIT CODE J160


EUROPE

02/2004

STEER COLUMN
ITEM

PART NO.

a 1379488
a 2067410

DESCRIPTION

QTY

Nut ...............................................................................................................................
Jumper Assembly ........................................................................................................

1
1

FOOTNOTES:
a Not Illustrated
b Optional
c Used with optional 305 mm steer wheel

4-14

See Service Manual


for service procedures.

2004 HYSTER COMPANY

NOTES

4-15

UNIT CODE J160


EUROPE

02/2004

STEER PUMP AND MOTOR (Figure 4-6)

4-16

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

STEER PUMP AND MOTOR


ITEM

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

PART NO.

2048105
39362
2033614
1545227
16745
222504
292681
293613
1545522
292679
302244
214364
320158
292681
317594
a 2066967
a 130845

QTY

DESCRIPTION

Steer Motor (48V) ........................................................................................................


O-Ring .........................................................................................................................
Gear Pump ( Figure 4-1) ........................................................................................
Weldment.....................................................................................................................
Fitting...........................................................................................................................
Fitting...........................................................................................................................
Lockwasher..................................................................................................................
Capscrew.....................................................................................................................
Spacer .........................................................................................................................
Lockwasher..................................................................................................................
Screw...........................................................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Grommet......................................................................................................................
Hose ............................................................................................................................
Clamp ..........................................................................................................................

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

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

4-17

UNIT CODE J160


EUROPE

02/2004

STEER TIRE AND WHEEL ASSEMBLY (Figure 4-7)


SOLID PNEUMATIC

ITEM

1
2

PART NO.

1523995
2054827
a .. . . .

DESCRIPTION

QTY

Tire and Wheel Assembly............................................................................................


Tire ..........................................................................................................................
Wheel Weldment .........................................................................................................

2
1
1

FOOTNOTES:
a Not Serviced Separately

4-18

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

5 BRAKE/ACCELERATOR SYST EM

BRAKE/ACCELERATOR SYSTEM

02/2004

UNIT CODE J160


EUROPE

SECTION 5
BRAKE/ACCELERATOR SYSTEM
DESCRIPTION

PAGE

ACCELERATOR ASSEMBLY .............................................................................................................................. 5-2


ACCELERATOR PEDAL....................................................................................................................................... 5-4
BRAKE ASSEMBLY ............................................................................................................................................. 5-6
MASTER CYLINDER ........................................................................................................................................... 5-8
PARKING BRAKE............................................................................................................................................... 5-10

2004 HYSTER COMPANY

See Service Manual


for service procedures.

5-1

UNIT CODE J160


EUROPE

02/2004

ACCELERATOR ASSEMBLY (Figure 5-1)

5-2

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

ACCELERATOR ASSEMBLY
ITEM

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

PART NO.

2066719
2053601
1364281
1335110
915474
1354990
325799
320154
292678
302027
292667
302026
320157
292681
176640
1343624
1340985
320159
292522
136692
292681
239503
214364
1522424
1528707
1528708
1528709
1340989
1486770
1486737
136985
292682
292515
a 2062742

QTY

DESCRIPTION

Accelerator Assembly ..................................................................................................


Accelerator Weldment .............................................................................................
Stop .........................................................................................................................
Switch......................................................................................................................
Insulator...................................................................................................................
Sensor .....................................................................................................................
Electrical Connector ................................................................................................
Washer ....................................................................................................................
Lockwasher .............................................................................................................
Screw ......................................................................................................................
Nut...........................................................................................................................
Screw ......................................................................................................................
Washer ....................................................................................................................
Lockwasher .............................................................................................................
Capscrew ................................................................................................................
Pad ..............................................................................................................................
Tube .............................................................................................................................
Washer ........................................................................................................................
Capscrew.....................................................................................................................
Nut ...............................................................................................................................
Lockwasher..................................................................................................................
Nut ...............................................................................................................................
Capscrew.....................................................................................................................
O-Ring .........................................................................................................................
Hydraulic Tube (RH) ....................................................................................................
Hydraulic Tube (LH) .....................................................................................................
Hydraulic Tube (Brake Line) ........................................................................................
Spring ..........................................................................................................................
Fitting...........................................................................................................................
Fitting...........................................................................................................................
Capscrew.....................................................................................................................
Lockwasher..................................................................................................................
Capscrew.....................................................................................................................
Jumper Assembly ........................................................................................................

1
1
2
1
1
1
1
4
4
2
4
2
4
4
2
1
1
7
1
5
1
2
1
1
1
1
1
1
1
3
2
2
4
1

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

5-3

UNIT CODE J160


EUROPE

02/2004

ACCELERATOR PEDAL (Figure 5-2)

5-4

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

ACCELERATOR PEDAL
KEY:
A: Monotrol Pedal
B: Forward/Reverse
QTY
ITEM

PART NO.

DESCRIPTION

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

1340988
1377414
1340975
1340976
368618
310436
1340470
352885
1475250
325699
53162
16865
16708
15931
362036
114312
220428

Accelerator Pedal ................................................................................................


Accelerator Pedal ................................................................................................
Pedal ...............................................................................................................
Pedal ...............................................................................................................
Bushing ...........................................................................................................
Pin ...................................................................................................................
Pad ..................................................................................................................
Pad ..................................................................................................................
Switch Assembly .............................................................................................
Spring ..............................................................................................................
Lockwasher .....................................................................................................
Nut...................................................................................................................
Screw ..............................................................................................................
Lockwasher .....................................................................................................
Washer ............................................................................................................
Strap Clamp ....................................................................................................
Capscrew ........................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

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

1
..
..
1
2
1
..
1
..
..
..
..
..
..
..
..
..

5-5

UNIT CODE J160


EUROPE

02/2004

BRAKE ASSEMBLY (Figure 5-3)

5-6

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

BRAKE ASSEMBLY
QTY

ITEM

PART NO.

DESCRIPTION

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

1548469
1548462
1548473
1548475
320165
292573
316828
374160
1539854
1364281
320157
292681
176640
220281
2309196
1340998
2060613
296013
239503

Brake Assembly ...........................................................................................................


Brake Weldment ......................................................................................................
Brake Pedal .............................................................................................................
Tube.........................................................................................................................
Washer ....................................................................................................................
Capscrew ................................................................................................................
Nut...........................................................................................................................
Insulator...................................................................................................................
Brake Switch Assembly ...........................................................................................
Stop .........................................................................................................................
Washer ....................................................................................................................
Lockwasher .............................................................................................................
Capscrew ................................................................................................................
Screw ......................................................................................................................
Nut Plate Assembly .................................................................................................
Spring ......................................................................................................................
Master Cylinder ( Figure 5-4) .............................................................................
Capscrew ................................................................................................................
Nut...........................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

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

5-7

UNIT CODE J160


EUROPE

02/2004

MASTER CYLINDER (Figure 5-4)

5-8

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MASTER CYLINDER
ITEM

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

PART NO.

2060613
1556261
1556262
1556263
1556264
1556265
1556266
1556267
1556268
1556269
1556270
1556271
1556397
a 1556500

QTY

DESCRIPTION

Master Cylinder ...........................................................................................................


Stop Plate................................................................................................................
Push Rod.................................................................................................................
Yoke.........................................................................................................................
Nut...........................................................................................................................
Pin ...........................................................................................................................
Washer ....................................................................................................................
Snap Pin..................................................................................................................
Stop Pin...................................................................................................................
Filter ........................................................................................................................
Indicator...................................................................................................................
Clamp ......................................................................................................................
Boot .........................................................................................................................
Repair Kit.................................................................................................................

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

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

5-9

UNIT CODE J160


EUROPE

02/2004

PARKING BRAKE (Figure 5-5)

5-10

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

PARKING BRAKE
ITEM

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

a
a
a
a
a
a
a
a
a
a
a
a

QTY

PART NO.

DESCRIPTION

2053881
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
58929
32033

Brake ...........................................................................................................................
Brake Coil ....................................................................................................................
Spring ..........................................................................................................................
Pressure Plate .............................................................................................................
Spacer .........................................................................................................................
Shim ............................................................................................................................
Friction Disk .................................................................................................................
Mounting Plate.............................................................................................................
Screw...........................................................................................................................
Capscrew.....................................................................................................................
Lockwasher..................................................................................................................
Washer ........................................................................................................................
Wiring Harness ............................................................................................................
Snap Ring....................................................................................................................
Key...............................................................................................................................

1
1
6
1
3
12
1
1
3
4
4
4
1
2
2

FOOTNOTES:
a Not Serviced Separately

2004 HYSTER COMPANY

See Service Manual


for service procedures.

5-11

NOTES

5-12

UNIT CODE J160


EUROPE

02/2004

6 HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

02/2004

UNIT CODE J160


EUROPE

SECTION 6
HYDRAULIC SYSTEM
DESCRIPTION

PAGE

ELECTRO-HYDRAULIC AUXILIARY VALVE SECTION ...................................................................................... 6-2


ELECTRO-HYDRAULIC CONTROL VALVE ........................................................................................................ 6-4
ELECTRO-HYDRAULIC LEVERS........................................................................................................................ 6-6
ELECTRO-HYDRAULIC MAIN CONTROL VALVE SECTION ........................................................................... 6-22
ELECTRO-HYDRAULIC TILT VALVE SECTION ................................................................................................ 6-26
HANDLEVER........................................................................................................................................................ 6-8
HYDRAULIC GEAR PUMP ................................................................................................................................ 6-10
HYDRAULIC HOSE AND FITTINGS
ELECTRO ....................................................................................................................................................... 6-12
MANUAL ......................................................................................................................................................... 6-14
HYDRAULIC PUMP MOTOR ............................................................................................................................. 6-16
HYDRAULIC TANK ASSEMBLY......................................................................................................................... 6-18
HYDRAULIC VALVE AND ATTACHING PARTS
MANUAL ......................................................................................................................................................... 6-20
MANUAL CONTROL VALVE .............................................................................................................................. 6-24

2004 HYSTER COMPANY

See Service Manual


for service procedures.

6-1

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC AUXILIARY VALVE SECTION (Figure 6-1)

6-2

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC AUXILIARY VALVE SECTION


ITEM

1
2
3
4
5
6
7
8
9

PART NO.

QTY

DESCRIPTION

1558094
1556590
1556596
b .. . . .
1557186
1546684
1546686
1557189
1557190
a 1557191

Valve Section ...............................................................................................................


Actuator .......................................................................................................................
Block ............................................................................................................................
Solenoid Coil ...............................................................................................................
O-Ring .........................................................................................................................
O-Ring .........................................................................................................................
O-Ring .........................................................................................................................
O-Ring .........................................................................................................................
O-Ring .........................................................................................................................
O-Ring .........................................................................................................................

1
1
1
2
2
1
3
4
4
2

1544781

Seal Kit (Includes Items 5-10) .....................................................................................

FOOTNOTES:
a Not Illustrated
b Not Serviced Separately

2004 HYSTER COMPANY

See Service Manual


for service procedures.

6-3

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC CONTROL VALVE (Figure 6-2)

6-4

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC CONTROL VALVE


KEY:
A: Three Function
B: Four Function
QTY
ITEM

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

PART NO.

2062060
2062061
2062067
2062068
98599
201752
16560
16540
324972
325056
287817
320156
287851
320158
287854
320159
292682
136692
2798897
1546568
1546572
1546570
1546573
1556587
1556589
1558094
a 1544781

DESCRIPTION

Electro-Hydraulic Control Valve ...........................................................................


Electro-Hydraulic Control Valve ...........................................................................
Plate ....................................................................................................................
Plate ....................................................................................................................
Fitting...................................................................................................................
Fitting...................................................................................................................
Fitting...................................................................................................................
Fitting...................................................................................................................
Bracket.................................................................................................................
Channel (Rubber) ................................................................................................
Capscrew.............................................................................................................
Washer ................................................................................................................
Capscrew.............................................................................................................
Washer ................................................................................................................
Capscrew.............................................................................................................
Washer ................................................................................................................
Lockwasher..........................................................................................................
Nut .......................................................................................................................
Plate ....................................................................................................................
Washer ................................................................................................................
Tension Rod.........................................................................................................
Screw...................................................................................................................
Nut .......................................................................................................................
Connection Block.................................................................................................
Valve Section .......................................................................................................
Valve Section .......................................................................................................
Seal Kit ................................................................................................................

1
..
1
..
1
1
1
1
3
3
1
1
2
2
3
3
3
3
1
2
..
2
..
1
1
1
1

..
1
..
1
1
1
1
1
3
3
1
1
2
2
3
3
3
3
1
2
2
..
2
1
1
2
1

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

6-5

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC LEVERS (Figure 6-3)

6-6

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC LEVERS
ITEM

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

QTY

PART NO.

DESCRIPTION

2061994
1553671
1555731
2065094
1553671
136687
2061995
1553671
1555731
2065095
1553671
292680
320156

Control Handle (Three Function) .................................................................................


Software ..................................................................................................................
Kit ............................................................................................................................
Control Handle (Three Function Clamping) .................................................................
Software ..................................................................................................................
Nut ...............................................................................................................................
Control Handle (Four Function) ...................................................................................
Software ..................................................................................................................
Kit ............................................................................................................................
Control Handle (Four Function Clamping) ...................................................................
Software ..................................................................................................................
Lockwasher..................................................................................................................
Washer ........................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
1
3
1
1
4
1
1
4
1
1
4
4

6-7

UNIT CODE J160


EUROPE

02/2004

HANDLEVER (Figure 6-4)

6-8

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HANDLEVER
QTY

ITEM

PART NO.

DESCRIPTION

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

1330574
1529139
2065362
2065363
2065364
2065365
292501
320156
292680
136687
2062064
2306052
287817
2303365
15200
2308059
2305669
296153
293778
2302179
292501
320156
302399
19979
175861
2309570
2304767
2304087
2307513
2303898
15200
2013239
2309978
307253
2311392
2310972
1547231
1510861

Capscrew.....................................................................................................................
Cover (Upper) ..............................................................................................................
Handlever (Lift) ............................................................................................................
Handlever (Tilt) ............................................................................................................
Handlever (Aux 1) ........................................................................................................
Handlever (Last Function) ...........................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Nut ...............................................................................................................................
Spacer .........................................................................................................................
Spacer .........................................................................................................................
Capscrew.....................................................................................................................
Knob ............................................................................................................................
Cotter Pin.....................................................................................................................
Rod ..............................................................................................................................
Latch ............................................................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Strap ............................................................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Nut ...............................................................................................................................
Pin ...............................................................................................................................
Spring ..........................................................................................................................
Crank ...........................................................................................................................
Pivot.............................................................................................................................
Crank ...........................................................................................................................
Spacer .........................................................................................................................
Link ..............................................................................................................................
Cotter Pin.....................................................................................................................
Pin ...............................................................................................................................
Rocker Arm..................................................................................................................
Snap Ring....................................................................................................................
Pivot Pin.......................................................................................................................
Bearing ........................................................................................................................
Frame ..........................................................................................................................
Nut Plate Assembly .....................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

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

6-9

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC GEAR PUMP (Figure 6-5)

6-10

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC GEAR PUMP


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

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

PART NO.

DESCRIPTION

2069006
2303239
1371741
.. . . .
1371744
1371743
.. . . .
2052235
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
.. . . .
ab 1460539

Gear Pump ..........................................................................................................


Retaining Ring.................................................................................................
Seal .................................................................................................................
Flange..................................................................................................................
Back-Up Ring ..................................................................................................
Seal .................................................................................................................
Bushing ...........................................................................................................
O-Ring .............................................................................................................
Pump Body......................................................................................................
Idler Gear ........................................................................................................
Drive Gear .......................................................................................................
Cover ...................................................................................................................
Bolt ......................................................................................................................
Bolt ......................................................................................................................
O-Ring .................................................................................................................

..
1
1
1
4
4
2
2
1
1
1
1
4
..
2

1
1
1
1
4
4
2
2
1
1
1
1
..
4
2

1371746

Seal Kit (Includes Items 1-2, 4-5, 7) ....................................................................

FOOTNOTES:
a Included in Seal Kit 1371746
b Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

6-11

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC HOSE AND FITTINGS (Figure 6-6)


ELECTRO

6-12

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC HOSE AND FITTINGS


ELECTRO
KEY:
A: Two Function
B: Three Function
C: Four Function
A

ITEM

PART NO.

DESCRIPTION

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

2061806
1563712
2068750
2062827
1526744
1520416
292515
320159
2307638
16457
2068747
2068746
2068749
2068748

Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose .........................................................................................................
Plate .........................................................................................................
Capscrew..................................................................................................
Washer .....................................................................................................
Fastener....................................................................................................
Fitting........................................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
1
1
1
1
..
..
..
..
..
..
..
..
..

QTY
B

1
1
1
1
1
1
2
2
2
2
1
1
..
..

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

6-13

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC HOSE AND FITTINGS (Figure 6-7)


MANUAL

6-14

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC HOSE AND FITTINGS


MANUAL
KEY:
A: Two Function
B: Three Function
C: Four Function
ITEM

PART NO.

DESCRIPTION

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

2061805
2068717
2062824
2062825
2061808
1520416
292515
320159
2307638
16457
2068747
2068746
2068749
2068748
2065755
16556
17059
2062822
2062823
1460672
16679
1526656
127045
166857
292515
292519
292682
320159
136692
317594
1356113
1548223
1548225
129563
178119
287851
136749
292681
320157
239503

Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose .........................................................................................................
Plate .........................................................................................................
Capscrew..................................................................................................
Washer .....................................................................................................
Fastener....................................................................................................
Fitting........................................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hoist Motor Bracket ..................................................................................
Fitting........................................................................................................
Fitting........................................................................................................
Hose Assembly.........................................................................................
Hose Assembly.........................................................................................
Hose .........................................................................................................
Rivet..........................................................................................................
Hose .........................................................................................................
Clamp .......................................................................................................
Clamp .......................................................................................................
Capscrew..................................................................................................
Capscrew..................................................................................................
Lockwasher...............................................................................................
Washer .....................................................................................................
Nut ............................................................................................................
Grommet...................................................................................................
Washer .....................................................................................................
Spacer ......................................................................................................
Bracket Weldment.....................................................................................
Strap Clamp..............................................................................................
Clamp .......................................................................................................
Capscrew..................................................................................................
Capscrew..................................................................................................
Lockwasher...............................................................................................
Washer .....................................................................................................
Nut ............................................................................................................

a
a
a
a
a
a

QTY
B

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

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

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

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

6-15

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC PUMP MOTOR (Figure 6-8)

6-16

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC PUMP MOTOR


QTY

ITEM

PART NO.

DESCRIPTION

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

2065366
1502724
1502725
1502726
1502727
1502728
1564327
1502730
1502731
1564328
1502733
1500182
1502735
1502736

Hydraulic Pump Motor .................................................................................................


Bracket ....................................................................................................................
Bearing ....................................................................................................................
Armature .................................................................................................................
Gasket .....................................................................................................................
Plate ........................................................................................................................
Stator.......................................................................................................................
Brush Holder ...........................................................................................................
Brush (with Spring)..................................................................................................
Thermal Protector ...................................................................................................
Commutator.............................................................................................................
Bearing ....................................................................................................................
Fan ..........................................................................................................................
Cover .......................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

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

6-17

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC TANK ASSEMBLY (Figure 6-9)

6-18

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC TANK ASSEMBLY


QTY

ITEM

PART NO.

DESCRIPTION

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

2054280
2059683
2042698
1532304
88195
17221
287851
136749
292681
320157
292679
16655
2068733

Hydraulic Tank .............................................................................................................


Breather .......................................................................................................................
Hydraulic Oil Filter Assembly.......................................................................................
Switch Assembly..........................................................................................................
Fitting...........................................................................................................................
Fitting...........................................................................................................................
Capscrew.....................................................................................................................
Capscrew.....................................................................................................................
Lockwasher..................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Capscrew.....................................................................................................................
Ground Wire ................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

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

6-19

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC VALVE AND ATTACHING PARTS (Figure 6-10)


MANUAL

6-20

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HYDRAULIC VALVE AND ATTACHING PARTS


MANUAL
QTY

ITEM

PART NO.

DESCRIPTION

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

1330574
1529140
2311384
2062063
287817
1520417
15200
2013239
2303498
58903
2307900
19979
175861
2307042
2303162
324972
287854
320159
292682
136692
325056
2062057
2062058
287860
320159
292682
136692
2062072

Capscrew.....................................................................................................................
2
Lower Cover ................................................................................................................
1
Standoff .......................................................................................................................
1
Standoff .......................................................................................................................
1
Capscrew.....................................................................................................................
2
Link ..............................................................................................................................
2
Cotter Pin.....................................................................................................................
4
Pin ...............................................................................................................................
4
Pin ...............................................................................................................................
2
Snap Ring....................................................................................................................
4
Shim ............................................................................................................................ AR
Pin ...............................................................................................................................
1
Spring ..........................................................................................................................
1
Pin ...............................................................................................................................
1
Spacer .........................................................................................................................
2
Bracket.........................................................................................................................
5
Capscrew.....................................................................................................................
1
Washer ........................................................................................................................
1
Lockwasher..................................................................................................................
1
Nut ...............................................................................................................................
1
Channel (Rubber) ........................................................................................................
5
Control Valve (Three Spool Valve)...............................................................................
1
Control Valve (Four Spool Valve) .................................................................................
1
Capscrew.....................................................................................................................
1
Washer ........................................................................................................................
1
Lockwasher..................................................................................................................
1
Nut ...............................................................................................................................
1
Bracket Weldment........................................................................................................
1

2004 HYSTER COMPANY

See Service Manual


for service procedures.

6-21

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC MAIN CONTROL VALVE SECTION (Figure 6-11)

6-22

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC MAIN CONTROL VALVE SECTION


ITEM

1
2
3
4
5
6
7
8
9
10
11

PART NO.

1556587
1544349
1544327
1544344
1544345
1544346
a .. . . .
1544347
a .. . . .
a .. . . .
1544349

QTY

DESCRIPTION

Connection Block.........................................................................................................
Valve ............................................................................................................................
Piston...........................................................................................................................
Spring Guide................................................................................................................
Spring ..........................................................................................................................
Disc..............................................................................................................................
Seal Ring .....................................................................................................................
Screw...........................................................................................................................
Seal .............................................................................................................................
Screw...........................................................................................................................
Valve ............................................................................................................................

1
1
1
1
1
1
1
1
1
1
2

FOOTNOTES:
a Not Serviced Separately

2004 HYSTER COMPANY

See Service Manual


for service procedures.

6-23

UNIT CODE J160


EUROPE

02/2004

MANUAL CONTROL VALVE (Figure 6-12)

6-24

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MANUAL CONTROL VALVE


ITEM

1
2
3
4
5
6
a
a
a
a

QTY

PART NO.

DESCRIPTION

2062057
2062058
1547585
1551544
1551545
1551546
1551547
1547586
2046006
1554622
1554623
1557699

Control Valve (Three Spool Valve)...............................................................................


Control Valve (Four Spool Valve) .................................................................................
Inlet Section .................................................................................................................
Lift Section...................................................................................................................
Tilt Section...................................................................................................................
Auxiliary One Section (Three and Four Function) .......................................................
Auxiliary Two Section (Four Function) .........................................................................
Outlet Section ..............................................................................................................
Manifold (Three Function)............................................................................................
Switch and Bracket Kit (Lift Section)............................................................................
Switch and Bracket Kit (Tilt/Auxiliary Section) .............................................................
Seal Kit ........................................................................................................................

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

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

6-25

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC TILT VALVE SECTION (Figure 6-13)

6-26

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

ELECTRO-HYDRAULIC TILT VALVE SECTION


ITEM

1
2
3
4
5
6
7
8
9

PART NO.

QTY

DESCRIPTION

1556589
1556590
1544364
b .. . . .
1557186
1546684
1546686
1557189
1557190
a 1557191

Valve Section ...............................................................................................................


Actuator .......................................................................................................................
Block ............................................................................................................................
Solenoid Coil ...............................................................................................................
O-Ring .........................................................................................................................
O-Ring .........................................................................................................................
O-Ring .........................................................................................................................
O-Ring .........................................................................................................................
O-Ring .........................................................................................................................
O-Ring .........................................................................................................................

1
1
1
2
2
1
3
4
4
2

1544781

Seal Kit (Includes Items 5-10) .....................................................................................

FOOTNOTES:
a Not Illustrated
b Not Serviced Separately

2004 HYSTER COMPANY

See Service Manual


for service procedures.

6-27

NOTES

6-28

UNIT CODE J160


EUROPE

02/2004

7 MAST-TWO STAGE LIMITED FREE-LIFT

MAST-TWO STAGE LIMITED FREE-LIFT

02/2004

UNIT CODE J160


EUROPE

SECTION 7
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION

PAGE

CARRIAGE
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-2
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-4
INNER MAST
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6
INTEGRAL SIDE-SHIFT CARRIAGE
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-8
MAIN LIFT ASSEMBLY
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-10
MAIN LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-12
OUTER MAST
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-14
SIDE-SHIFT CYLINDER .................................................................................................................................... 7-16

2004 HYSTER COMPANY

See Service Manual


for service procedures.

7-1

UNIT CODE J160


EUROPE

02/2004

CARRIAGE (Figure 7-1)


TWO STAGE LIMITED FREE-LIFT

ITEM

PART NO.

DESCRIPTION

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

2055495
1526274
1345216
58901
1374797
129387
366115
1353192
1333399
1393132
1369345
1504010
1353408
131358
1514866
15211

Carriage.......................................................................................................................
1
Frame ..........................................................................................................................
1
Stubshaft .................................................................................................................
6
Snap Ring....................................................................................................................
6
Snap Ring (Optional) ...................................................................................................
6
Shim (0,508 mm) ......................................................................................................... AR
Spacer .........................................................................................................................
2
Load Roller ..................................................................................................................
6
Load Roller (Optional) .................................................................................................
6
Load Roller (Optional) .................................................................................................
6
Chain Anchor (Dual Hole)............................................................................................
2
Chain Anchor (Single Hole) (Optional) ........................................................................
2
Pin ...............................................................................................................................
2
Snap Ring....................................................................................................................
4
Pin ...............................................................................................................................
2
Cotter Pin.....................................................................................................................
2

7-2

QTY

See Service Manual


for service procedures.

2004 HYSTER COMPANY

NOTES

7-3

UNIT CODE J160


EUROPE

02/2004

HEADER HOSE (Figure 7-2)


TWO STAGE LIMITED FREE-LIFT

7-4

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HEADER HOSE
TWO STAGE LIMITED FREE-LIFT

DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
1
Hose

LIFT HEIGHT TO BOTTOM OF FORKS


A661
3292
1564626

A661
3792
1564631

A661
4292
1564636

KEY:
A: Three Function
B: Four Function
QTY
ITEM

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

PART NO.

b .. . . .
a 1360508
a 1353530
292508
1345412
1345413
313828
1363486
1360548
1494017
1345190
313805
292533
1360386
292683
136704
292502
1360507
1345348
1360507
1375574
1360549
16693

DESCRIPTION

Hose ....................................................................................................................
Clamp ..................................................................................................................
Clamp ..................................................................................................................
Capscrew.............................................................................................................
Bracket (RH) ........................................................................................................
Bracket (LH).........................................................................................................
Nut .......................................................................................................................
Bracket.................................................................................................................
Stubshaft .............................................................................................................
Sheave.................................................................................................................
Washer ................................................................................................................
Nut .......................................................................................................................
Capscrew.............................................................................................................
Clamp ..................................................................................................................
Lockwasher..........................................................................................................
Capscrew.............................................................................................................
Capscrew.............................................................................................................
Clamp ..................................................................................................................
Clamp ..................................................................................................................
Clamp ..................................................................................................................
Strap ....................................................................................................................
Spacer .................................................................................................................
Fitting...................................................................................................................

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

4
2
8
4
..
1
6
1
1
1
2
2
1
1
1
2
2
2
2
4
2
1
2

FOOTNOTES:
a 149 in., 157 in., and 168 in. Lifts
b Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

7-5

UNIT CODE J160


EUROPE

02/2004

INNER MAST (Figure 7-3)


TWO STAGE LIMITED FREE-LIFT

7-6

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

INNER MAST
TWO STAGE LIMITED FREE-LIFT

DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
Mast Assembly
1
Inner Mast

ITEM

1
2
3
4
5
6
7
8
9
10

PART NO.

a .. . . .
a .. . . .
1345216
1353192
58901
129387
304526
1379685
1378698
1378699
37752

LIFT HEIGHT TO BOTTOM OF FORKS


A661
3292
2055751

A661
3792
2055756

A661
4292
2055758

1348459

1348464

1348469

DESCRIPTION

QTY

Mast Assembly ............................................................................................................


1
Inner Mast....................................................................................................................
1
Stubshaft.............................................................................................................
2
Load Roller ..............................................................................................................
2
Snap Ring................................................................................................................
2
Shim (0,508 mm)..................................................................................................... AR
Snap Ring................................................................................................................
2
Chain Sheave Assembly .........................................................................................
2
Sheave ................................................................................................................
1
Bearing................................................................................................................
1
Snap Ring ...........................................................................................................
2

FOOTNOTES:
a Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

7-7

UNIT CODE J160


EUROPE

02/2004

INTEGRAL SIDE-SHIFT CARRIAGE (Figure 7-4)


TWO STAGE LIMITED FREE-LIFT

7-8

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

INTEGRAL SIDE-SHIFT CARRIAGE


TWO STAGE LIMITED FREE-LIFT
QTY

ITEM

PART NO.

DESCRIPTION

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

2056867
1529598
1489010
2043528
2043531
2043533
2043530
226458
296426
1401746
18832
16041
1353192
1333399
1393132
58901
1374797
129387
366115
1369345
1504010
1353408
131358
1514866
15211
1498326

Side-Shift Carriage ......................................................................................................


1
Frame (Inner) ...............................................................................................................
1
Frame (965 mm) (Outer)..............................................................................................
1
Cylinder Assembly .......................................................................................................
1
Bearing (Upper) ...........................................................................................................
2
Bearing (Lower) ...........................................................................................................
2
Hook (Lower) ...............................................................................................................
2
Capscrew.....................................................................................................................
4
Washer (Hardened) .....................................................................................................
4
Pin ...............................................................................................................................
2
Cotter Pin.....................................................................................................................
2
Lube Fitting ..................................................................................................................
2
Load Roller ..................................................................................................................
6
Load Roller (Optional) .................................................................................................
6
Load Roller (Optional) .................................................................................................
6
Snap Ring....................................................................................................................
6
Snap Ring (Optional) ...................................................................................................
6
Shim (0,508 mm) ......................................................................................................... 28
Spacer .........................................................................................................................
2
Chain Anchor (Dual Hole)............................................................................................
2
Chain Anchor (Single Hole) (Optional) ........................................................................
2
Pin ...............................................................................................................................
2
Snap Ring....................................................................................................................
4
Pin ...............................................................................................................................
2
Cotter Pin.....................................................................................................................
2
Shim ............................................................................................................................ AR

2004 HYSTER COMPANY

See Service Manual


for service procedures.

7-9

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT ASSEMBLY (Figure 7-5)


TWO STAGE LIMITED FREE-LIFT

7-10

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT ASSEMBLY


TWO STAGE LIMITED FREE-LIFT

DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
Mast Assembly
25 Chain

ITEM

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

PART NO.

a .. . . .
.. . . .
.. . . .
60137
296426
292532
296422
323090
300937
16560
16485
16982
323061
1333392
1379687
292509
313828
17051
120938
323160
189595
16485
14603
16486
131358
1333382
1354915
1354917
1354916
1514866
15211
1369357
a .. . . .
1376101
1376100
16882

LIFT HEIGHT TO BOTTOM OF FORKS


A661
3292
2055751

A661
3792
2055756

A661
4292
2055758

135634

177352

336391

DESCRIPTION

QTY

Mast Assembly ............................................................................................................


1
Lift Cylinder (LH)..........................................................................................................
1
Lift Cylinder (RH) .........................................................................................................
1
Nut ...............................................................................................................................
2
Washer (Hardened) .....................................................................................................
2
Capscrew.....................................................................................................................
2
Washer ........................................................................................................................
4
Spacer .........................................................................................................................
2
Nut ...............................................................................................................................
2
Fitting...........................................................................................................................
2
O-Ring .....................................................................................................................
1
O-Ring .........................................................................................................................
1
Control Valve ...............................................................................................................
1
Housing .......................................................................................................................
1
Housing (Optional).......................................................................................................
1
Capscrew.....................................................................................................................
2
Nut ...............................................................................................................................
2
Fitting...........................................................................................................................
1
Spring ..........................................................................................................................
1
Washer ........................................................................................................................
1
Fitting...........................................................................................................................
1
O-Ring .........................................................................................................................
1
Fitting (Optional) ..........................................................................................................
1
O-Ring (Optional) ........................................................................................................
1
Snap Ring....................................................................................................................
2
Washer ........................................................................................................................
2
Washer ........................................................................................................................ AR
Washer ........................................................................................................................ AR
Washer ........................................................................................................................ AR
Pin ...............................................................................................................................
2
Cotter Pin.....................................................................................................................
2
Chain Anchor ...............................................................................................................
2
Chain ...........................................................................................................................
2
Hose ............................................................................................................................
2
Hose ............................................................................................................................
2
Fitting...........................................................................................................................
1

FOOTNOTES:
a Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

7-11

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT CYLINDER (Figure 7-6)


TWO STAGE LIMITED FREE-LIFT

7-12

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT CYLINDER


TWO STAGE LIMITED FREE-LIFT

LEFT HAND
DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
Lift Cylinder
7
Rod
15

Shell

LIFT HEIGHT TO BOTTOM OF FORKS


A661
3292
1361372

A661
3792
1362527

A661
4292
1362557

1361374

1362529

1362559

1361373

1362528

1362558

RIGHT HAND
DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
Lift Cylinder
7
Rod
15

ITEM

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

Shell

PART NO.

LIFT HEIGHT TO BOTTOM OF FORKS


A661
3292
1361376

A661
3792
1362531

A661
4292
1362561

1361374

1362529

1362559

1361377

1362532

1362562

DESCRIPTION

QTY

b .. . . .
1319668
322824
1381095
1371653
55407
322902
b .. . . .
322824
330692
1362871
257913
39348
297531
637635
187388
b .. . . .
a 1355189

Lift Cylinder..................................................................................................................
Wiper Ring...............................................................................................................
Back-Up Ring ..........................................................................................................
Rod Seal..................................................................................................................
Gland.......................................................................................................................
O-Ring .....................................................................................................................
Wear Ring ...............................................................................................................
Rod..........................................................................................................................
Back-Up Ring ..........................................................................................................
Seal .........................................................................................................................
Wear Ring ...............................................................................................................
Check Valve.............................................................................................................
O-Ring .....................................................................................................................
Washer ....................................................................................................................
Washer ........................................................................................................................
Snap Ring (Optional)...............................................................................................
Shell ........................................................................................................................
Spacer .........................................................................................................................

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

1360140

Seal Kit (Includes Items 1-6, 8-9) ................................................................................

FOOTNOTES:
a Not Illustrated
b Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

7-13

UNIT CODE J160


EUROPE

02/2004

OUTER MAST (Figure 7-7)


TWO STAGE LIMITED FREE-LIFT

7-14

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

OUTER MAST
TWO STAGE LIMITED FREE-LIFT

DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
Mast Assembly
1
Outer Mast

ITEM

1
2
3
4
5
6
6
6
7
8
9

PART NO.

a .. . . .
a .. . . .
1345216
215212
131716
104506
1353192
1333399
1393132
58901
129387
1348185

LIFT HEIGHT TO BOTTOM OF FORKS


A661
3292
2055751

A661
3792
2055756

A661
4292
2055758

1526872

1526877

1526883

DESCRIPTION

QTY

Mast Assembly ............................................................................................................


1
Outer Mast...............................................................................................................
1
Stubshaft.............................................................................................................
2
Bearing Strip ...........................................................................................................
2
Shim (0,508 mm).....................................................................................................
4
O-Ring .....................................................................................................................
4
Load Roller ..............................................................................................................
2
Load Roller ..................................................................................................................
2
Load Roller ..................................................................................................................
2
Snap Ring................................................................................................................
2
Shim (0,508 mm)..................................................................................................... AR
Bushing ...................................................................................................................
2

FOOTNOTES:
a Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

7-15

UNIT CODE J160


EUROPE

02/2004

SIDE-SHIFT CYLINDER (Figure 7-8)

ITEM

1
2
3
4
5
6

7-16

PART NO.

DESCRIPTION

QTY

2043528
1489016
1489037
1489035
1498325
1489039
302487

Cylinder Assembly .......................................................................................................


Cylinder ...................................................................................................................
Rod Seal..................................................................................................................
O-Ring .....................................................................................................................
Retainer...................................................................................................................
Rod Wiper ...............................................................................................................
Pin ...........................................................................................................................

1
1
2
2
2
2
1

1503096

Seal Kit (Includes Items 2-3, 5) ...............................................................................

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

8 MAST-T HREE STAGE FULL FREE-LIFT

MAST-THREE STAGE FULL FREE-LIFT

02/2004

UNIT CODE J160


EUROPE

SECTION 8
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION

PAGE

CARRIAGE
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-2
FREE LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-4
FREE LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-6
HEADER HOSE
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-8
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-12
INTEGRAL SIDE-SHIFT CARRIAGE
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-14
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-16
MAIN LIFT ASSEMBLY
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-18
MAIN LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-22
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-24
TILT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-26
TILT CYLINDER ATTACHING PARTS
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-28

2004 HYSTER COMPANY

See Service Manual


for service procedures.

8-1

UNIT CODE J160


EUROPE

02/2004

CARRIAGE (Figure 8-1)


THREE STAGE FULL FREE-LIFT

ITEM

PART NO.

DESCRIPTION

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

2055493
1526275
1345216
58901
1374797
129387
366115
1363272
1393142
1369345
1504010
1353408
131358
1514866
15211

Carriage.......................................................................................................................
1
Frame ..........................................................................................................................
1
Stubshaft .................................................................................................................
6
Snap Ring....................................................................................................................
6
Snap Ring (Optional) ...................................................................................................
6
Shim (0,508 mm) ......................................................................................................... AR
Spacer .........................................................................................................................
2
Load Roller ..................................................................................................................
6
Load Roller (Optional) .................................................................................................
6
Chain Anchor (Dual Hole)............................................................................................
2
Chain Anchor (Single Hole) (Optional) ........................................................................
2
Pin ...............................................................................................................................
2
Snap Ring....................................................................................................................
4
Pin ...............................................................................................................................
2
Cotter Pin.....................................................................................................................
2

8-2

QTY

See Service Manual


for service procedures.

2004 HYSTER COMPANY

NOTES

8-3

UNIT CODE J160


EUROPE

02/2004

FREE LIFT (Figure 8-2)


THREE STAGE FULL FREE-LIFT

8-4

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

FREE LIFT
THREE STAGE FULL FREE-LIFT

DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
Mast Assembly
1
Chain
2

ITEM

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

Hose

PART NO.

a .. . . .
a .. . . .
a .. . . .
60137
296426
1514866
15211
1369357
1395285
292527
.. . . .
1353547
302461
1489972
292528
320161
300937
1379496
1337905
292533
1360534
1343989
1354901
1379685
37752
1378699
1378698
304526
131358
.. . . .

LIFT HEIGHT TO BOTTOM OF FORKS


A662
4460
2055834

A662
4760
2055836

A662
4910
2055837

A662
5510
2055841

231082

231083

231084

88436

1363306

1363308

1363309

1363313

DESCRIPTION

QTY

Mast Assembly ............................................................................................................


Chain .......................................................................................................................
Hose ........................................................................................................................
Nut...........................................................................................................................
Washer (Hardened) .................................................................................................
Pin ...........................................................................................................................
Cotter Pin ................................................................................................................
Chain Anchor...........................................................................................................
Chain Guard ............................................................................................................
Capscrew ................................................................................................................
Lockwasher .............................................................................................................
Bracket ....................................................................................................................
Pin ...........................................................................................................................
Bracket ....................................................................................................................
Capscrew ................................................................................................................
Washer ....................................................................................................................
Nut...........................................................................................................................
Valve........................................................................................................................
Crosshead ...............................................................................................................
Capscrew ................................................................................................................
Stubshaft .................................................................................................................
Hose Sheave ...........................................................................................................
Bushing ...............................................................................................................
Chain Sheave Assembly .........................................................................................
Snap Ring ...........................................................................................................
Bearing................................................................................................................
Sheave ................................................................................................................
Snap Ring................................................................................................................
Snap Ring................................................................................................................
Free Lift Cylinder .....................................................................................................

1
2
1
2
2
2
2
2
2
2
3
1
2
1
4
6
4
1
1
1
1
1
1
2
2
1
1
2
1
1

FOOTNOTES:
a Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

8-5

UNIT CODE J160


EUROPE

02/2004

FREE LIFT CYLINDER (Figure 8-3)


THREE STAGE FULL FREE-LIFT

8-6

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

FREE LIFT CYLINDER


THREE STAGE FULL FREE-LIFT

DESCRIPTION
1 2 3 4
Mast
ITEM
Group Number
Cylinder
Group Number
Lift Cylinder
1
Shell
2

ITEM

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

Rod

PART NO.

LIFT HEIGHT TO BOTTOM OF FORKS


A662
4460

A662
4760

A662
4910

A662
5510

8601906

8601908

8601909

8601914

1362886

1362888

1362889

1362894

1362923

1362925

1362926

1362931

1362960

1362962

1362963

1362968

DESCRIPTION

QTY

a .. . . .
a .. . . .
a .. . . .
2013099
1358970
1362880
147973
55146
2013089
201829
1362881
257913
190580
297531
187388
1361302
190887

Lift Cylinder..................................................................................................................
Shell ........................................................................................................................
Rod..........................................................................................................................
Wiper .......................................................................................................................
Seal .........................................................................................................................
Gland.......................................................................................................................
Back-Up Ring ..........................................................................................................
O-Ring .....................................................................................................................
Back-Up Ring ..........................................................................................................
Rod Seal..................................................................................................................
Wear Ring ...............................................................................................................
Check Valve.............................................................................................................
O-Ring .....................................................................................................................
Washer ....................................................................................................................
Snap Ring................................................................................................................
Screw ......................................................................................................................
Seal .........................................................................................................................

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

1360141

Seal Kit (Includes Items 3-4, 6-10, 12, 16) ..................................................................

FOOTNOTES:
a Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

8-7

UNIT CODE J160


EUROPE

02/2004

HEADER HOSE (Figure 8-4)


THREE STAGE FULL FREE-LIFT

8-8

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HEADER HOSE
THREE STAGE FULL FREE-LIFT

DESCRIPTION
1 2 3 4
Mast
ITEM
Group Number
Cylinder
Group Number
1
Hose

LIFT HEIGHT TO BOTTOM OF FORKS


A662
4460

A662
4760

A662
4910

A662
5510

1547115

1547117

1547118

1547122

KEY:
A: Three Function
B: Four Function
QTY
ITEM

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

PART NO.

a .. . . .
1363253
1363256
.. . . .
136704
136749
313828
1345199
1345204
1369333
1396406
1494017
.. . . .
1381598
1381599
1345190
292533
320161
300937
1360549
293795
293795
313805
1360386
1353464
1348247
1348246
292521
320160
316826
1353530
1360507
1375574

2004 HYSTER COMPANY

DESCRIPTION

Hose ....................................................................................................................
Bracket (RH) ........................................................................................................
Bracket (LH).........................................................................................................
Bracket.................................................................................................................
Capscrew.............................................................................................................
Capscrew.............................................................................................................
Nut .......................................................................................................................
Hose Guide..........................................................................................................
Snap Ring............................................................................................................
Clamp ..................................................................................................................
Stubshaft .............................................................................................................
Sheave.................................................................................................................
Bushing ...........................................................................................................
Bracket (RH) ........................................................................................................
Bracket (LH).........................................................................................................
Washer ................................................................................................................
Capscrew.............................................................................................................
Washer ................................................................................................................
Nut .......................................................................................................................
Spacer .................................................................................................................
Capscrew.............................................................................................................
Capscrew.............................................................................................................
Nut .......................................................................................................................
Clamp ..................................................................................................................
Plate ....................................................................................................................
Hose Guide..........................................................................................................
Hose Guide..........................................................................................................
Capscrew.............................................................................................................
Washer ................................................................................................................
Nut .......................................................................................................................
Clamp ..................................................................................................................
Clamp ..................................................................................................................
Strap ....................................................................................................................

See Service Manual


for service procedures.

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

4
1
1
1
4
12
12
4
4
2
2
2
1
1
1
2
2
2
2
2
4
4
4
4
1
1
1
2
4
2
8
4
4

8-9

UNIT CODE J160


EUROPE

02/2004

HEADER HOSE
THREE STAGE FULL FREE-LIFT
ITEM

PART NO.

DESCRIPTION

32
33

1395292
1395291

Bracket (LH).........................................................................................................
Bracket (RH) ........................................................................................................

..
1

QTY
B

1
1

FOOTNOTES:
a Refer to Table

8-10

See Service Manual


for service procedures.

2004 HYSTER COMPANY

NOTES

8-11

UNIT CODE J160


EUROPE

02/2004

INNER MAST (Figure 8-5)


THREE STAGE FULL FREE-LIFT

8-12

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

INNER MAST
THREE STAGE FULL FREE-LIFT

DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
Mast Assembly
1
Inner Mast

ITEM

1
2
3
4
5

PART NO.

a .. . . .
a .. . . .
1345264
58901
129387
1353192

LIFT HEIGHT TO BOTTOM OF FORKS


A662
4460
2055834

A662
4760
2055836

A662
4910
2055837

A662
5510
2055841

1352806

1352808

1352809

1352813

DESCRIPTION

QTY

Mast Assembly ............................................................................................................


1
Inner Mast ...............................................................................................................
1
Stubshaft.............................................................................................................
2
Snap Ring................................................................................................................
2
Shim (0,508 mm)..................................................................................................... AR
Load Roller ..............................................................................................................
2

FOOTNOTES:
a Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

8-13

UNIT CODE J160


EUROPE

02/2004

INTEGRAL SIDE-SHIFT CARRIAGE (Figure 8-6)


THREE STAGE FULL FREE-LIFT

8-14

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

INTEGRAL SIDE-SHIFT CARRIAGE


THREE STAGE FULL FREE-LIFT
QTY

ITEM

PART NO.

DESCRIPTION

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

2056866
1529596
1489010
2043528
2043531
2043533
2043530
226458
296426
1401746
18832
16041
317735
1369345
1504010
131358
1514866
15211
1363272
1393142
129387
366115
58901
1374797
1498326

Side-Shift Carriage ......................................................................................................


1
Frame (Inner)...........................................................................................................
1
Frame (965 mm) (Outer) .........................................................................................
1
Cylinder Assembly...................................................................................................
1
Bearing (Upper).......................................................................................................
2
Bearing (Lower).......................................................................................................
2
Hook (Lower) ...........................................................................................................
2
Capscrew ................................................................................................................
4
Washer (Hardened) .................................................................................................
4
Pin ...........................................................................................................................
2
Cotter Pin ................................................................................................................
2
Lube Fitting..............................................................................................................
2
Pin ...........................................................................................................................
2
Chain Anchor (Dual Hole) .......................................................................................
2
Chain Anchor (Single Hole) (Optional) ....................................................................
2
Snap Ring................................................................................................................
4
Pin ...........................................................................................................................
2
Cotter Pin ................................................................................................................
2
Load Roller ..............................................................................................................
6
Load Roller (Optional) .................................................................................................
6
Shim (0,508 mm)..................................................................................................... 28
Spacer .....................................................................................................................
2
Snap Ring................................................................................................................
6
Snap Ring (Optional) ...................................................................................................
6
Shim ........................................................................................................................ AR

2004 HYSTER COMPANY

See Service Manual


for service procedures.

8-15

UNIT CODE J160


EUROPE

02/2004

INTERMEDIATE MAST (Figure 8-7)


THREE STAGE FULL FREE-LIFT

8-16

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT

DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
Mast Assembly
1
Intermediate Mast

ITEM

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

PART NO.

a .. . . .
a .. . . .
1345264
215212
131716
104506
1353191
58901
129387
230518
1379685
1378698
1378699
37752

LIFT HEIGHT TO BOTTOM OF FORKS


A662
4460
2055834

A662
4760
2055836

A662
4910
2055837

A662
5510
2055841

1353006

1353008

1353009

1353013

DESCRIPTION

QTY

Mast Assembly ............................................................................................................


1
Intermediate Mast ...................................................................................................
1
Stubshaft.............................................................................................................
4
Bearing Strip ...........................................................................................................
2
Shim (0,508 mm).....................................................................................................
4
O-Ring .....................................................................................................................
4
Load Roller ..............................................................................................................
4
Snap Ring................................................................................................................
4
Shim (0,508 mm)..................................................................................................... AR
Plug .........................................................................................................................
2
Chain Sheave Assembly .........................................................................................
2
Sheave ................................................................................................................
1
Bearing................................................................................................................
1
Snap Ring ...........................................................................................................
2

FOOTNOTES:
a Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

8-17

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT ASSEMBLY (Figure 8-8)


THREE STAGE FULL FREE-LIFT

8-18

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT ASSEMBLY


THREE STAGE FULL FREE-LIFT

DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
Mast Assembly
1
Chain

ITEM

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

PART NO.

a .. . . .
a .. . . .
.. . . .
.. . . .
292531
296422
323090
300937
131358
1333382
1354915
1354916
1354917
136681
313828
1363250
287851
1363251
1353399
323061
16982
1333392
16560
16485
16543
16486
1376100
1376101
17051
120938
323160
189595
16485
1369357
1514866
15211
1365140
15223
60137

2004 HYSTER COMPANY

LIFT HEIGHT TO BOTTOM OF FORKS


A662
4460
2055834

A662
4760
2055836

A662
4910
2055837

A662
5510
2055841

164474

88441

135634

177352

DESCRIPTION

QTY

Mast Assembly ............................................................................................................


1
Chain ...........................................................................................................................
2
Lift Cylinder (LH)..........................................................................................................
1
Lift Cylinder (RH) .........................................................................................................
1
Capscrew.....................................................................................................................
2
Washer ........................................................................................................................
4
Spacer .........................................................................................................................
2
Nut ...............................................................................................................................
2
Snap Ring....................................................................................................................
2
Washer ........................................................................................................................
2
Washer (0,254 mm) ..................................................................................................... AR
Washer (0,762 mm) ..................................................................................................... AR
Washer (1,524 mm) ..................................................................................................... AR
Capscrew.....................................................................................................................
2
Nut ...............................................................................................................................
4
Plate ............................................................................................................................
1
Capscrew.....................................................................................................................
2
Clamp ..........................................................................................................................
1
Tube .............................................................................................................................
1
Control Valve ...............................................................................................................
1
O-Ring .....................................................................................................................
1
Housing .......................................................................................................................
1
Fitting...........................................................................................................................
2
O-Ring .....................................................................................................................
1
Fitting...........................................................................................................................
1
O-Ring .....................................................................................................................
1
Hose ............................................................................................................................
1
Hose ............................................................................................................................
1
Fitting...........................................................................................................................
1
Spring ..........................................................................................................................
2
Washer ........................................................................................................................
2
Fitting...........................................................................................................................
2
O-Ring .....................................................................................................................
1
Chain Anchor ...............................................................................................................
2
Pin ...............................................................................................................................
4
Cotter Pin.....................................................................................................................
4
Chain Anchor ...............................................................................................................
2
Cotter Pin.....................................................................................................................
2
Nut ...............................................................................................................................
4

See Service Manual


for service procedures.

8-19

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT ASSEMBLY


THREE STAGE FULL FREE-LIFT
ITEM

33
34

PART NO.

DESCRIPTION

QTY

296426
16882

Washer (Hardened) .....................................................................................................


Fitting ...........................................................................................................................

4
1

FOOTNOTES:
a Refer to Table

8-20

See Service Manual


for service procedures.

2004 HYSTER COMPANY

NOTES

8-21

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT CYLINDER (Figure 8-9)


THREE STAGE FULL FREE-LIFT

8-22

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT CYLINDER


THREE STAGE FULL FREE-LIFT

LEFT HAND
DESCRIPTION
1 2 3 4
Mast
ITEM
Group Number
Cylinder
Group Number
Lift Cylinder
1
Shell
2

Rod

LIFT HEIGHT TO BOTTOM OF FORKS


A662
4460

A662
4760

A662
4910

A662
5510

8601706

8601708

8601709

8601713

1362702

1362715

1362721

1362745

1362703

1362716

1362722

1366057

1362704

1362717

1362723

1362746

RIGHT HAND
DESCRIPTION
1 2 3 4
Mast
ITEM
Group Number
Cylinder
Group Number
Lift Cylinder
1
Shell
2

ITEM

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

Rod

PART NO.

LIFT HEIGHT TO BOTTOM OF FORKS


A662
4460

A662
4760

A662
4910

A662
5510

8601756

8601758

8601759

8601763

1362706

1362719

1362725

1362749

1362713

1362726

1362732

1362756

1362704

1362717

1362723

1362746

DESCRIPTION

QTY

a .. . . .
a .. . . .
a .. . . .
1371653
1355610
257913
297531
187388
190580
1319668
1381095
55407
330692
322824
1362871
1362875
322902

Lift Cylinder..................................................................................................................
Shell ........................................................................................................................
Rod..........................................................................................................................
Gland.......................................................................................................................
Spacer .....................................................................................................................
Check Valve.............................................................................................................
Washer ....................................................................................................................
Snap Ring................................................................................................................
O-Ring .....................................................................................................................
Wiper Ring...............................................................................................................
Rod Seal..................................................................................................................
O-Ring .....................................................................................................................
Seal .........................................................................................................................
Back-Up Ring ..........................................................................................................
Wear Ring ...............................................................................................................
Piston Ring ..............................................................................................................
Wear Ring ...............................................................................................................

1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1

1360139

Seal Kit (Includes Items 8-15) .....................................................................................

FOOTNOTES:
a Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

8-23

UNIT CODE J160


EUROPE

02/2004

OUTER MAST (Figure 8-10)


THREE STAGE FULL FREE-LIFT

8-24

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

OUTER MAST
THREE STAGE FULL FREE-LIFT

DESCRIPTION
1
2
3 4
ITEM
Mast
Group Number
Mast Assembly
1
Outer Mast

ITEM

1
2
3
4
5
6
7
8
9

PART NO.

a .. . . .
a .. . . .
1345264
215212
131716
104506
1353192
58901
129387
1348185

LIFT HEIGHT TO BOTTOM OF FORKS


A662
4460
2055834

A662
4760
2055836

A662
4910
2055837

A662
5510
2055841

1526869

1526871

1526872

1526877

DESCRIPTION

QTY

Mast Assembly ............................................................................................................


1
Outer Mast...............................................................................................................
1
Stubshaft.............................................................................................................
2
Bearing Strip ...........................................................................................................
2
Shim (0,508 mm).....................................................................................................
4
O-Ring .....................................................................................................................
4
Load Roller ..............................................................................................................
2
Snap Ring................................................................................................................
2
Shim (0,508 mm)..................................................................................................... AR
Bushing ...................................................................................................................
2

FOOTNOTES:
a Refer to Table

2004 HYSTER COMPANY

See Service Manual


for service procedures.

8-25

UNIT CODE J160


EUROPE

02/2004

TILT CYLINDER (Figure 8-11)


THREE STAGE FULL FREE-LIFT

8-26

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

TILT CYLINDER
THREE STAGE FULL FREE-LIFT
KEY:
A: 5 Forward Tilt/7 Back Tilt
B: 10 Forward Tilt/5 Back Tilt
C: 5 Forward Tilt/5 Back Tilt
ITEM

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

PART NO.

DESCRIPTION

QTY
B

2054598
2054599
2054600
2302899
.. . . .
2308174
2307659
2311444
2050282
2054601
2054602
.. . . .
.. . . .
.. . . .
2047064
.. . . .
a 39374

Tilt Cylinder (Group No. 8603391) ...........................................................


Tilt Cylinder (Group No. 8604718) ...........................................................
Tilt Cylinder (Group No. 8604719) ...........................................................
Nut........................................................................................................
Seal ......................................................................................................
Piston ...................................................................................................
Piston Rod............................................................................................
Piston Rod............................................................................................
Piston Rod............................................................................................
Tube......................................................................................................
Tube......................................................................................................
Seal ......................................................................................................
O-Ring ..................................................................................................
Back-up Ring........................................................................................
Gland....................................................................................................
Wiper Ring............................................................................................
O-Ring ......................................................................................................

..
2
..
1
1
1
1
..
..
1
..
1
1
1
1
1
1

2
..
..
1
1
1
..
1
..
..
1
1
1
1
1
1
1

..
..
2
1
1
1
..
..
1
1
..
1
1
1
1
1
1

1494719

Seal Kit (Includes Items 2, 6-8, 10) ......................................................

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

8-27

UNIT CODE J160


EUROPE

02/2004

TILT CYLINDER ATTACHING PARTS (Figure 8-12)


THREE STAGE FULL FREE-LIFT

8-28

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

TILT CYLINDER ATTACHING PARTS


THREE STAGE FULL FREE-LIFT
ITEM

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

PART NO.

293651
292683
292656
292514
292682
1371287
16001
1348187
1363260
1363261
2054598
2054599
2054600
1371526
16001
15236
197069
300982
1523880
15865
1523879
a 1523877

QTY

DESCRIPTION

Capscrew.....................................................................................................................
Lockwasher..................................................................................................................
Nut ...............................................................................................................................
Capscrew.....................................................................................................................
Lockwasher..................................................................................................................
Washer ........................................................................................................................
Lube Fitting ..................................................................................................................
Rod End Pin ................................................................................................................
Rod End.......................................................................................................................
Rod End.......................................................................................................................
Tilt Cylinder (Group No. 8603391) ..............................................................................
Tilt Cylinder (Group No. 8604718) ..............................................................................
Tilt Cylinder (Group No. 8604719) ..............................................................................
Rod End Pin ................................................................................................................
Lube Fitting ..................................................................................................................
Cotter Pin.....................................................................................................................
Washer ........................................................................................................................
Bushing........................................................................................................................
Spacer .........................................................................................................................
O-Ring .........................................................................................................................
Shim ............................................................................................................................
Bushing........................................................................................................................

2
2
2
2
2
2
2
2
1
1
1
1
1
2
2
2
6
2
2
2
2
2

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

8-29

NOTES

8-30

UNIT CODE J160


EUROPE

02/2004

9 MAST-TWO STAGE F ULL FREE-LIFT

MAST-TWO STAGE FULL FREE-LIFT

02/2004

UNIT CODE J160


EUROPE

SECTION 9
MAST-TWO STAGE FULL FREE-LIFT
DESCRIPTION

PAGE

CARRIAGE
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-2
FREE LIFT
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-4
HEADER HOSE
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-6
INNER MAST
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-8
INTEGRAL SIDE-SHIFT CARRIAGE
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-10
MAIN LIFT ASSEMBLY
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-12
MAIN LIFT CYLINDER
LEFT HAND
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-14
RIGHT HAND
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-16
OUTER MAST
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-18

2004 HYSTER COMPANY

See Service Manual


for service procedures.

9-1

UNIT CODE J160


EUROPE

02/2004

CARRIAGE (Figure 9-1)


TWO STAGE FULL FREE-LIFT

ITEM

PART NO.

DESCRIPTION

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

2055494
1526276
1345216
58901
1374797
129387
366115
1353192
1333399
1393132
1369345
1504010
1353408
131358
1514866
15211

Carriage.......................................................................................................................
1
Frame ..........................................................................................................................
1
Stubshaft .....................................................................................................................
6
Snap Ring....................................................................................................................
6
Snap Ring (Optional) ...................................................................................................
6
Shim (0,508 mm) ......................................................................................................... AR
Spacer .........................................................................................................................
2
Load Roller ..................................................................................................................
6
Load Roller (Optional) .................................................................................................
6
Load Roller (Optional) .................................................................................................
6
Chain Anchor (Dual Hole)............................................................................................
2
Chain Anchor (Single Hole) (Optional) .......................................................................
2
Pin ...............................................................................................................................
2
Snap Ring....................................................................................................................
4
Pin ...............................................................................................................................
2
Cotter Pin.....................................................................................................................
2

9-2

QTY

See Service Manual


for service procedures.

2004 HYSTER COMPANY

NOTES

9-3

UNIT CODE J160


EUROPE

02/2004

FREE LIFT (Figure 9-2)


TWO STAGE FULL FREE-LIFT

9-4

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

FREE LIFT
TWO STAGE FULL FREE-LIFT
QTY

ITEM

PART NO.

DESCRIPTION

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

2055885
231083
1365308
60137
296426
1514866
15211
1369357
1395285
132860
292683
1353546
302461
1489972
292528
320161
300937
1379496
16485
1378690
320158
.. . . .
132861
178119
239503
1380035
16484
16882
304526
1379682
37752
1378699
1378692
1362888
131358
166112
296422

Mast Assembly ............................................................................................................


Chain .......................................................................................................................
Hose ........................................................................................................................
Nut...........................................................................................................................
Washer (Hardened) .................................................................................................
Pin ...........................................................................................................................
Cotter Pin ................................................................................................................
Chain Anchor...........................................................................................................
Chain Guard ............................................................................................................
Capscrew ................................................................................................................
Lockwasher .............................................................................................................
Bracket ....................................................................................................................
Pin ...........................................................................................................................
Bracket ....................................................................................................................
Capscrew ................................................................................................................
Washer ....................................................................................................................
Nut...........................................................................................................................
Valve........................................................................................................................
O-Ring.................................................................................................................
Crosshead ...............................................................................................................
Washer ....................................................................................................................
Lockwasher .............................................................................................................
Capscrew ................................................................................................................
Clamp ......................................................................................................................
Nut...........................................................................................................................
Fitting.......................................................................................................................
O-Ring.................................................................................................................
Fitting.......................................................................................................................
Snap Ring................................................................................................................
Chain Sheave Assembly .........................................................................................
Snap Ring ...........................................................................................................
Bearing................................................................................................................
Sheave ................................................................................................................
Lift Cylinder .............................................................................................................
Snap Ring................................................................................................................
Clamp ......................................................................................................................
Washer ........................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

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

9-5

UNIT CODE J160


EUROPE

02/2004

HEADER HOSE (Figure 9-3)


TWO STAGE FULL FREE-LIFT

9-6

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

HEADER HOSE
TWO STAGE FULL FREE-LIFT
KEY:
A: Three-Function
B: Four-Function
QTY
ITEM

PART NO.

DESCRIPTION

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

1365504
1365516
1345573
1345576
1353530
1360508
1360507
1360386
1345423
1354918
293795
.. . . .
1369333
136749
313828
1345199
1345204
2004005
1365061
14692
1375574
1353638
1353668
365115
293799

Channel ...............................................................................................................
Channel ...............................................................................................................
Hose ....................................................................................................................
Hose ....................................................................................................................
Clamp ..................................................................................................................
Clamp ..................................................................................................................
Clamp ..................................................................................................................
Clamp ..................................................................................................................
Clamp ..................................................................................................................
Bracket.................................................................................................................
Capscrew.............................................................................................................
Bracket.................................................................................................................
Clamp ..................................................................................................................
Capscrew.............................................................................................................
Nut .......................................................................................................................
Hose Guide..........................................................................................................
Snap Ring............................................................................................................
Strap Clamp.........................................................................................................
Clip ......................................................................................................................
Fitting...................................................................................................................
Strap ....................................................................................................................
Tube .....................................................................................................................
Tube .....................................................................................................................
Hose ....................................................................................................................
Capscrew.............................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

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

1
1
..
2
5
4
3
3
2
1
2
1
1
2
2
2
2
2
1
2
4
1
1
4
4

9-7

UNIT CODE J160


EUROPE

02/2004

INNER MAST (Figure 9-4)


TWO STAGE FULL FREE-LIFT

9-8

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

INNER MAST
TWO STAGE FULL FREE-LIFT
ITEM

1
2
3
4
5

QTY

PART NO.

DESCRIPTION

2055885
1352908
1345264
1353192
58901
129387

Mast Assembly ............................................................................................................


1
Inner Mast ...............................................................................................................
1
Stubshaft.............................................................................................................
2
Load Roller ..............................................................................................................
2
Snap Ring................................................................................................................
2
Shim (0,508 mm)..................................................................................................... AR

2004 HYSTER COMPANY

See Service Manual


for service procedures.

9-9

UNIT CODE J160


EUROPE

02/2004

INTEGRAL SIDE-SHIFT CARRIAGE (Figure 9-5)


TWO STAGE FULL FREE-LIFT

9-10

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

INTEGRAL SIDE-SHIFT CARRIAGE


TWO STAGE FULL FREE-LIFT
QTY

ITEM

PART NO.

DESCRIPTION

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

2056865
1529600
1489010
2043528
2043531
2043533
2043530
226458
296426
1401746
18832
16041
317735
1369345
1504010
131358
1514866
15211
1353192
1333399
1393132
129387
366115
58901
1374797
1498326

Side-Shift Carriage ......................................................................................................


1
Frame (Inner)...........................................................................................................
1
Frame (965 mm) (Outer) .........................................................................................
1
Cylinder Assembly...................................................................................................
1
Bearing (Upper).......................................................................................................
2
Bearing (Lower).......................................................................................................
2
Hook (Lower) ...........................................................................................................
2
Capscrew ................................................................................................................
4
Washer (Hardened) .................................................................................................
4
Pin ...........................................................................................................................
2
Cotter Pin ................................................................................................................
2
Lube Fitting..............................................................................................................
2
Pin ...........................................................................................................................
2
Chain Anchor (Dual Hole) .......................................................................................
2
Chain Anchor (Single Hole) (Optional) ....................................................................
2
Snap Ring................................................................................................................
4
Pin ...........................................................................................................................
2
Cotter Pin ................................................................................................................
2
Load Roller ..............................................................................................................
6
Load Roller (Optional) .................................................................................................
6
Load Roller (Optional) .................................................................................................
6
Shim (0,508 mm)..................................................................................................... 28
Spacer .....................................................................................................................
2
Snap Ring................................................................................................................
6
Snap Ring (Optional) ...................................................................................................
6
Shim ........................................................................................................................ AR

2004 HYSTER COMPANY

See Service Manual


for service procedures.

9-11

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT ASSEMBLY (Figure 9-6)


TWO STAGE FULL FREE-LIFT

9-12

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT ASSEMBLY


TWO STAGE FULL FREE-LIFT
QTY

ITEM

PART NO.

DESCRIPTION

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

.. . . .
.. . . .
292532
296422
323090
300937
131358
1333382
1354915
1354916
1354917
323061
16982
1379687
1333392
292509
313828
17051
120938
323160
189595
16485
14603
16486
16560
16485
1376100
1376101
16882

Lift Cylinder (LH)..........................................................................................................


1
Lift Cylinder (RH) .........................................................................................................
1
Capscrew.....................................................................................................................
2
Washer ........................................................................................................................
4
Spacer .........................................................................................................................
2
Nut ...............................................................................................................................
2
Snap Ring....................................................................................................................
2
Washer ........................................................................................................................
2
Washer ........................................................................................................................ AR
Washer ........................................................................................................................ AR
Washer ........................................................................................................................ AR
Control Valve ...............................................................................................................
1
O-Ring .....................................................................................................................
1
Housing .......................................................................................................................
1
Housing (Optional).......................................................................................................
1
Capscrew.....................................................................................................................
2
Nut ...............................................................................................................................
2
Fitting...........................................................................................................................
1
Spring ..........................................................................................................................
1
Washer ........................................................................................................................
1
Fitting...........................................................................................................................
1
O-Ring .....................................................................................................................
1
Fitting (Optional) ..........................................................................................................
1
O-Ring (Optional) ....................................................................................................
1
Fitting...........................................................................................................................
2
O-Ring .....................................................................................................................
1
Hose ............................................................................................................................
1
Hose ............................................................................................................................
1
Fitting...........................................................................................................................
1

2004 HYSTER COMPANY

See Service Manual


for service procedures.

9-13

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT CYLINDER (Figure 9-7)


LEFT HAND
TWO STAGE FULL FREE-LIFT

9-14

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT CYLINDER


LEFT HAND
TWO STAGE FULL FREE-LIFT
QTY

ITEM

PART NO.

DESCRIPTION

1
2
3
4
5
6
7
8
9
10
11

2046367
1365607
1365666
1310369
1381082
1498116
132834
55407
1374802
1362875
295649
190887

Lift Cylinder..................................................................................................................
Shell ........................................................................................................................
Rod..........................................................................................................................
Wiper Ring...............................................................................................................
Seal .........................................................................................................................
Gland.......................................................................................................................
Back-Up Ring ..........................................................................................................
O-Ring .....................................................................................................................
Wear Ring ...............................................................................................................
Piston Ring ..............................................................................................................
Screw ......................................................................................................................
Seal .........................................................................................................................

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

1498115

Seal Kit (Includes Items 3-4, 6-8, 11) ..........................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

9-15

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT CYLINDER (Figure 9-8)


RIGHT HAND
TWO STAGE FULL FREE-LIFT

9-16

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

MAIN LIFT CYLINDER


RIGHT HAND
TWO STAGE FULL FREE-LIFT
QTY

ITEM

PART NO.

DESCRIPTION

1
2
3
4
5
6
7
8
9
10

2046336
1365607
1365637
1310369
1381082
1498116
132834
55407
1362871
295649
190887

Lift Cylinder..................................................................................................................
Shell ........................................................................................................................
Rod..........................................................................................................................
Wiper Ring...............................................................................................................
Seal .........................................................................................................................
Gland.......................................................................................................................
Back-Up Ring ..........................................................................................................
O-Ring .....................................................................................................................
Wear Ring ...............................................................................................................
Screw ......................................................................................................................
Seal .........................................................................................................................

1
1
1
1
1
1
1
1
1
1
1

1498115

Seal Kit (Includes Items 3-4, 6-7, 10) ..........................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

9-17

UNIT CODE J160


EUROPE

02/2004

OUTER MAST (Figure 9-9)


TWO STAGE FULL FREE-LIFT

9-18

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

OUTER MAST
TWO STAGE FULL FREE-LIFT
ITEM

1
2
3
4
5
6
7
8
9

QTY

PART NO.

DESCRIPTION

2055885
1526871
1345264
215212
131716
104506
1353191
58901
129387
1348185

Mast Assembly ............................................................................................................


1
Outer Mast...............................................................................................................
1
Stubshaft.............................................................................................................
2
Bearing Strip ...........................................................................................................
2
Shim (0,508 mm).....................................................................................................
4
O-Ring .....................................................................................................................
4
Load Roller ..............................................................................................................
2
Snap Ring................................................................................................................
2
Shim (0,508 mm)..................................................................................................... AR
Bushing ...................................................................................................................
2

2004 HYSTER COMPANY

See Service Manual


for service procedures.

9-19

NOTES

9-20

UNIT CODE J160


EUROPE

02/2004

10 OPTIONS

10

OPTIONS

02/2004

UNIT CODE J160


EUROPE

SECTION 10
OPTIONS
DESCRIPTION

PAGE

BACKUP ALARM ............................................................................................................................................... 10-2


BATTERY SPACER ............................................................................................................................................ 10-4
DC CONVERTER
36/48 VOLT TO 12 VOLT ................................................................................................................................ 10-6
PREMIUM ....................................................................................................................................................... 10-8
FRONT LIGHT.................................................................................................................................................. 10-10
INTEGRAL SIDESHIFT
HYDRAULIC HOSES.................................................................................................................................... 10-12
INTERFACE CABLE......................................................................................................................................... 10-13
TAIL LIGHT....................................................................................................................................................... 10-14
WORK LIGHT................................................................................................................................................... 10-16
WORK LIGHT/STROBE COMBINATION ......................................................................................................... 10-18

2004 HYSTER COMPANY

See Service Manual


for service procedures.

10-1

UNIT CODE J160


EUROPE

02/2004

BACKUP ALARM (Figure 10-1)

10-2

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

BACKUP ALARM
ITEM

1
2
3
4
5
6
7
8

QTY

PART NO.

DESCRIPTION

2066700
1557145
1367645
316678
292501
320156
292680
136687

Audible Alarm ..............................................................................................................


Bracket.........................................................................................................................
Grommet......................................................................................................................
Screw...........................................................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Nut ...............................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
1
1
2
2
2
2
2

10-3

UNIT CODE J160


EUROPE

02/2004

BATTERY SPACER (Figure 10-2)

10-4

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

BATTERY SPACER
ITEM

1
1
1
2
2
3
4
5
6

QTY

PART NO.

DESCRIPTION

1545299
1545300
1545301
1545303
1545304
292519
320159
292682
136692

Battery Tray (1.6T) .......................................................................................................


Battery Tray (1.8T) .......................................................................................................
Battery Tray (2.0T) .......................................................................................................
Door Weldment (1.6T) .................................................................................................
Door Weldment (1.8 and 2.0T) ....................................................................................
Capscrew.....................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Nut ...............................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
1
1
1
1
2
2
2
2

10-5

UNIT CODE J160


EUROPE

02/2004

DC CONVERTER (Figure 10-3)


36/48 VOLT TO 12 VOLT

10-6

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

DC CONVERTER
36/48 VOLT TO 12 VOLT
ITEM

1
2
3
4
5
6
7
8
9

QTY

PART NO.

DESCRIPTION

292500
320156
292680
136687
292501
2037359
2306436
1390575
15127

Capscrew.....................................................................................................................
Washer ........................................................................................................................
Lockwasher..................................................................................................................
Nut ...............................................................................................................................
Capscrew.....................................................................................................................
Mounting Bracket.........................................................................................................
Panel Assembly ...........................................................................................................
DC Converter...............................................................................................................
Washer ........................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

2
2
9
5
7
1
1
1
6

10-7

UNIT CODE J160


EUROPE

02/2004

DC CONVERTER (Figure 10-4)


PREMIUM

10-8

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

DC CONVERTER
PREMIUM
ITEM

1
2
3
4

QTY

PART NO.

DESCRIPTION

1383195
292680
292501
292500

DC Converter (48V) .....................................................................................................


Lockwasher..................................................................................................................
Capscrew.....................................................................................................................
Capscrew.....................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

1
6
4
2

10-9

UNIT CODE J160


EUROPE

02/2004

FRONT LIGHT (Figure 10-5)

10-10

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

FRONT LIGHT
QTY

ITEM

PART NO.

DESCRIPTION

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

1554873
1554874
1518987
1557147
2067319
1534697
1531326
1367645
316678
2060639
1476421
316834
1382302
1382305

Worklight......................................................................................................................
Indicator Light ..............................................................................................................
Guard (Light) ...............................................................................................................
Bracket (Front Light) ....................................................................................................
Harness (Front Light)...................................................................................................
Plug .............................................................................................................................
Conduit ........................................................................................................................
Grommet......................................................................................................................
Screw...........................................................................................................................
Bolt ..............................................................................................................................
Washer ........................................................................................................................
Nut ...............................................................................................................................
Switch ..........................................................................................................................
Switch ..........................................................................................................................

2004 HYSTER COMPANY

See Service Manual


for service procedures.

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

10-11

UNIT CODE J160


EUROPE

02/2004

INTEGRAL SIDESHIFT (Figure 10-6)


HYDRAULIC HOSES

KEY:
A: Two Stage Limited Free-Lift
B: Three Stage Full Free-Lift
C: Two Stage Full Free-Lift
ITEM

1
1
1
2
2
3
4
4

10-12

PART NO.

DESCRIPTION

1503480
1503481
1503477
1503474
1489050
114312
16558
16483

Hose .........................................................................................................
Hose .........................................................................................................
Hose .........................................................................................................
Hose .........................................................................................................
Hose .........................................................................................................
Strap Clamp..............................................................................................
Fitting ........................................................................................................
O-Ring ......................................................................................................

See Service Manual


for service procedures.

..
..
1
..
1
1
2
2

QTY
B

1
..
..
1
..
1
2
2

..
1
..
..
1
1
2
2

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

INTERFACE CABLE (Figure 10-7)

ITEM

1
2
2

PART NO.

1534010
1532578
1534009
1532663
a 1539240
a 1542542

DESCRIPTION

QTY

Interface Cable ............................................................................................................


Interface Cable Adapter...........................................................................................
Wire Harness ..........................................................................................................
Connector ...........................................................................................................
Service Software .........................................................................................................
Service Software Data ............................................................................................

1
1
1
1
1
1

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

10-13

UNIT CODE J160


EUROPE

02/2004

TAIL LIGHT (Figure 10-8)

10-14

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

TAIL LIGHT
ITEM

1
2
3
4
5
6
7

PART NO.

2303953
1505178
2036284
1379615
1379616
1364542
a 1339779

QTY

DESCRIPTION

Tail Light ......................................................................................................................


Wire Harness...............................................................................................................
Spacer .........................................................................................................................
Plate ............................................................................................................................
Plate ............................................................................................................................
Clip Nut ........................................................................................................................
Screw...........................................................................................................................

2
2
4
2
2
4
4

FOOTNOTES:
a Not Illustrated

2004 HYSTER COMPANY

See Service Manual


for service procedures.

10-15

UNIT CODE J160


EUROPE

02/2004

WORK LIGHT (Figure 10-9)

10-16

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

WORK LIGHT
ITEM

1
2
3
4
5
6
7
8
9

QTY

PART NO.

DESCRIPTION

1554873
2067321
878959
1557146
1367645
176640
320157
292681
239503

Worklight......................................................................................................................
1
Harness (Rear Work Light) ..........................................................................................
1
Hose Guard ................................................................................................................. AR
Bracket.........................................................................................................................
1
Grommet......................................................................................................................
1
Capscrew.....................................................................................................................
2
Washer ........................................................................................................................
2
Lockwasher..................................................................................................................
2
Nut ...............................................................................................................................
2

2004 HYSTER COMPANY

See Service Manual


for service procedures.

10-17

UNIT CODE J160


EUROPE

02/2004

WORK LIGHT/STROBE COMBINATION (Figure 10-10)

10-18

See Service Manual


for service procedures.

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

WORK LIGHT/STROBE COMBINATION


ITEM

1
1
1
2
3
4
5
6
7
8
9

QTY

PART NO.

DESCRIPTION

1382130
1526082
1309775
1302024
1364588
878959
302250
320155
293778
292668
1367645

Strobe Light .................................................................................................................


1
Lens (Amber)...........................................................................................................
1
Bulb .........................................................................................................................
1
Guard...........................................................................................................................
1
Wire Harness (Light)....................................................................................................
1
Hose Guard ................................................................................................................. AR
Screw...........................................................................................................................
2
Washer ........................................................................................................................
4
Washer ........................................................................................................................
2
Nut ...............................................................................................................................
2
Grommet......................................................................................................................
1

2004 HYSTER COMPANY

See Service Manual


for service procedures.

10-19

NOTES

10-20

UNIT CODE J160


EUROPE

02/2004

11

NUMERICAL INDEX

UNIT CODE J160


EUROPE

02/2004

SECTION 11
NUMERICAL INDEX
PART NO. PG
14603
14692
15127
15134
15140
15156
15176
15200

15211

15212
15223
15236
15865
15931
16001
16041

16457
16483
16484
16485

16486

16540
16543
16556
16558
16560

7-11
9-13
9-7
10-7
4-13
1-11
4-13
1-3
6-9
6-9
6-21
7-2
7-9
7-11
8-2
8-5
8-15
8-19
9-2
9-5
9-11
4-13
8-19
8-29
8-29
5-5
8-29
8-29
7-9
8-15
9-11
6-13
6-15
10-12
9-5
7-11
7-11
8-19
8-19
9-5
9-13
9-13
7-11
8-19
9-13
6-5
8-19
6-15
10-12
6-5
7-11
8-19

ITEM
18
18
20
9
5
15
6
45
15
31
7
11
20
23
11
6
16
29
11
6
16
11
31
12
16
10
7
11
11
11
11
10
10
4
24
9
17
19
26
17
17
19
18
20
18
6
20
16
4
5
9
19

2004 HYSTER COMPANY

PART NO. PG
16655
16679
16693
16708
16745
16815
16865
16882

16982

17051

17059
17221
18832

19890
19979
32033
37752

39348
39362
39374
53162
55146
55407

58901

9-13
6-19
6-15
7-5
5-5
4-17
4-13
4-7
5-5
7-11
8-20
9-5
9-13
7-11
8-19
9-13
7-11
8-19
9-13
6-15
6-19
7-9
8-15
9-11
1-7
6-9
6-21
5-11
7-7
8-5
8-17
9-5
7-13
4-17
8-27
4-7
5-5
8-7
7-13
8-23
9-15
9-17
7-2
7-7
7-9
7-15
8-2
8-13
8-15
8-17
8-25
9-2

ITEM
19
12
21
23
9
5
7
19
8
27
34
25
21
10
17
10
14
23
14
17
6
10
10
10
3
24
12
14
10
23
13
28
12
2
11
18
7
7
5
11
7
7
3
4
13
7
3
3
20
7
7
3

PART NO.

58903
58929
60137

88195
88436
88441
98599
104506

114312
120938

127045
129387

129563
130845
131358

131716

See Service Manual


for service procedures.

PG
9-9
9-11
9-19
6-21
5-11
7-11
8-5
8-19
9-5
6-19
8-5
8-19
6-5
7-15
8-17
8-25
9-19
5-5
10-12
7-11
8-19
9-13
6-15
7-2
7-7
7-9
7-15
8-2
8-13
8-15
8-17
8-25
9-2
9-9
9-11
9-19
6-15
4-17
7-2
7-9
7-11
8-2
8-5
8-15
8-19
9-2
9-5
9-11
9-13
7-15
8-17
8-25

ITEM
4
20
7
10
13
3
3
32
3
5
1
1
3
5
5
5
5
12
3
15
24
15
23
4
5
14
8
4
4
18
8
8
4
5
18
8
34
17
9
18
19
9
27
14
8
9
32
14
7
4
4
4

PART NO. PG
132834
132860
132861
135634
136681

136687

136692

136704
136749

136985
147973
164474
166112
166857
167218
170658
175861
176640

177352

9-19
9-15
9-17
9-5
9-5
7-11
8-19
2-3
2-5
8-19
1-3
1-3
1-4
2-3
2-5
4-7
4-9
6-7
6-9
10-3
10-7
1-7
1-7
1-23
5-3
6-5
6-15
6-21
6-21
10-5
7-5
8-9
4-13
6-15
6-19
8-9
9-7
4-13
5-3
8-7
8-19
9-5
4-13
6-15
1-7
1-11
6-9
6-21
5-3
5-7
10-17
7-11

ITEM
4
6
6
9
21
25
1
7
7
11
4
16
72
4
4
6
43
2
10
8
4
8
16
8
19
16
29
20
26
6
16
4
16
37
8
5
14
42
30
6
1
33
24
24
5
9
25
13
14
12
6
25
11-1

UNIT CODE J160


EUROPE

02/2004

NUMERICAL INDEX (Continued)


PART NO.
178119
182118
187388

189595

190580
190811
190887

197069
201752
201829
214364
215212

216877
216895
220281
220426
220428
221771
221852
222399
222504
222523
226458

230518
231082
231083
231084
238950
239503

11-2

PG
8-19
6-15
9-5
1-3
1-3
7-13
8-7
8-23
7-11
8-19
9-13
8-7
8-23
2-3
2-5
8-7
9-15
9-17
8-29
6-5
8-7
4-17
5-3
7-15
8-17
8-25
9-19
1-19
1-23
5-7
4-7
5-5
1-17
1-3
4-10
4-17
2-16
7-9
8-15
9-11
8-17
8-5
8-5
9-5
8-5
1-11
1-3
5-3
5-7
6-15
9-5
10-17

ITEM
1
35
22
26
48
14
14
7
17
26
17
12
8
1
1
16
11
10
13
4
9
12
22
3
3
3
3
3
3
13
17
13
3
22
47
6
22
7
7
7
9
1
1
1
1
8
9
21
18
40
23
9

PART NO. PG
248196
257913

259665
269200
287817

287831
287851

287854
287860
292500

292501

292502
292507
292508
292509
292514
292515

292519

292521
292522
292527
292528
292531
292532

2-16
7-13
8-7
8-23
4-10
1-3
6-5
6-9
6-21
1-21
1-3
6-5
6-15
6-19
8-19
6-5
6-21
1-23
6-21
2-7
2-19
2-21
10-7
10-9
4-7
4-13
6-9
6-9
10-3
10-7
10-9
1-3
7-5
4-9
7-5
7-11
9-13
8-29
5-3
6-13
6-15
6-15
1-7
6-15
10-5
8-9
5-3
8-5
8-5
9-5
8-19
7-11

ITEM
22
11
11
5
49
41
9
13
5
19
40
11
36
7
14
13
17
4
23
18
21
22
1
4
14
37
7
21
5
5
3
13
17
40
4
12
12
4
32
7
7
25
10
26
3
26
18
9
14
14
4
5

PART NO. PG
292533

292573
292656
292667
292668
292678
292679

292680

292681

292682

See Service Manual


for service procedures.

9-13
7-5
8-5
8-9
5-7
1-17
8-29
5-3
10-19
5-3
2-11
4-17
6-19
1-3
1-4
2-3
2-5
2-7
2-19
2-19
2-21
2-21
4-7
4-13
6-7
6-9
10-3
10-7
10-9
1-3
1-3
1-4
2-3
2-5
4-13
4-17
4-17
5-3
5-3
5-7
6-15
6-19
10-17
1-3
1-7
1-7
1-23
4-13
5-3
6-5
6-15
6-21

ITEM
3
13
19
15
5
4
3
10
8
8
2
10
11
15
71
3
3
17
3
20
3
21
13
36
3
9
7
3
2
11
39
58
6
6
15
7
14
13
20
11
38
9
8
43
9
15
7
44
31
15
27
19

PART NO. PG

292683

293613
293629
293630
293651
293685
293706
293762
293778
293779
293795

293799

295649
296013
296153
296205
296247
296252
296420
296422

296423
296426

296431
296472
297531

300937

6-21
8-29
10-5
1-17
7-5
8-29
9-5
1-4
4-17
1-3
3-5
8-29
3-10
1-9
4-13
6-9
10-19
4-13
8-9
8-9
9-7
2-19
2-21
9-7
9-15
9-17
5-7
6-9
4-7
1-7
1-4
3-5
7-11
8-19
9-5
9-13
1-17
3-10
4-9
7-9
7-11
8-5
8-15
8-19
9-5
9-11
1-9
4-13
7-13
8-7
8-23
7-11

ITEM
25
5
5
5
15
2
10
57
8
44
5
1
46
2
9
19
7
8
19
20
11
4
4
25
10
9
17
18
9
12
61
4
6
5
34
4
3
45
35
8
4
4
8
33
4
8
3
30
13
13
6
8

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

NUMERICAL INDEX (Continued)


PART NO. PG

300982
302020
302026
302027
302048
302053
302054
302231
302244
302250
302398
302399
302400
302450
302461
302487
302977

304526

307253
310436
313805
313828

316448
316678

316826
316828
316834
317594
317735
320037
320154
320155

8-5
8-9
8-19
9-5
9-13
8-29
2-7
5-3
5-3
1-3
2-5
2-3
1-3
4-17
10-19
4-7
6-9
1-21
1-15
8-5
9-5
7-16
1-23
3-2
3-10
7-7
8-5
9-5
6-9
5-5
7-5
8-9
7-5
7-11
8-9
8-19
9-7
9-13
1-11
1-19
10-3
10-11
8-9
5-7
10-11
4-17
6-15
8-15
9-11
1-11
5-3
4-13

ITEM
16
17
7
16
6
14
14
11
9
2
2
2
21
11
5
7
23
9
5
12
12
6
2
3
47
6
26
26
34
3
12
21
7
13
6
12
15
13
25
5
4
9
28
6
12
15
30
12
12
6
7
18

2004 HYSTER COMPANY

PART NO. PG
320156

320157

320158

320159

320160
320161

320162
320165
322824

ITEM

10-19
1-3
1-3
1-4
2-19
2-19
2-21
2-21
4-7
4-13
6-5
6-7
6-9
6-9
10-3
10-7
1-4
1-21
5-3
5-7
6-15
6-19
10-17
1-3
1-3
4-17
6-5
9-5
1-3
1-7
1-23
4-13
5-3
6-5
6-13
6-15
6-15
6-21
6-21
10-5
1-23
8-9
1-3
1-4
8-5
8-9
9-5
1-19
5-7
7-13
7-13
8-23

6
3
14
70
2
19
2
20
12
35
10
4
8
22
6
2
56
8
12
10
39
10
7
10
38
13
12
19
42
14
6
43
17
14
8
8
28
18
24
4
5
27
25
51
15
16
15
2
4
2
8
13

PART NO.

PG

322902

7-13
8-23
7-11
8-19
9-13
7-11
8-19
9-13
7-11
8-19
9-13
6-5
6-21
6-5
6-21
5-5
5-3
2-7
7-13
8-23
7-11
5-5
4-3
4-3
4-3
4-3
4-3
4-3
1-7
1-3
5-5
9-7
7-2
7-9
8-2
8-15
9-2
9-11
5-5
1-3
1-11
1-11
5-7
2-5
4-13
2-7
2-15
2-15
2-15
2-16
2-16
2-16

323061

323090

323160

324972
325056
325699
325799
325810
330692
336391
352885
354669
354671
358069
358072
358073
358076
361973
362030
362036
365115
366115

368618
369242
370258
370259
374160
378383
379902
380689
381413

See Service Manual


for service procedures.

ITEM
6
16
10
17
10
7
6
5
16
25
16
7
16
8
21
6
6
19
9
12
25
4
3
8
5
4
10
9
13
17
11
24
5
15
5
19
5
19
2
8
31
32
7
1
26
20
4
8
11
27
28
32

PART NO. PG
383977
383979
383981
389688
392238
637635
878959
895468
915474
1302024
1305672
1306270
1306271
1309775
1309877
1310142
1310369
1319668
1322446
1322447
1322448
1327021
1327022
1327023
1329250
1330414
1330434
1330437
1330438

1330574
1333043
1333044
1333045
1333382

2-16
2-7
2-7
2-7
1-11
1-21
7-13
10-17
10-19
4-13
5-3
10-19
2-16
2-16
2-15
2-16
2-16
10-19
4-3
2-15
2-17
9-15
9-17
7-13
8-23
4-3
4-3
4-3
1-15
1-15
1-15
4-13
2-15
2-15
2-15
2-15
2-15
2-15
2-15
2-15
2-15
2-15
2-15
2-16
2-16
2-17
6-9
6-21
1-15
1-15
1-15
7-11

ITEM
46
9
9
9
14
10
13
3
4
33
4
2
25
30
2
23
24
1
11
3
53
3
3
1
9
12
13
14
1
1
1
21
12
17
18
12
1
13
14
15
16
17
18
26
31
50
1
1
1
1
1
20
11-3

UNIT CODE J160


EUROPE

02/2004

NUMERICAL INDEX (Continued)


PART NO.

1333392

1333399

1335110
1335967
1335987
1337196
1337905
1339396
1339667
1339672
1339674
1339779
1339828
1339830
1339832
1340470
1340975
1340976
1340985
1340988
1340989
1340998
1343276
1343537
1343572
1343573
1343574
1343577
1343578
1343579
1343593
1343594
1343595
1343597
1343598
1343607
1343624
1343647
1343989
1345190
1345199

11-4

PG
8-19
9-13
7-11
8-19
9-13
7-2
7-9
7-15
9-2
9-11
5-3
4-13
4-13
4-13
8-5
4-9
1-11
1-11
1-11
10-15
1-11
1-11
1-11
1-11
5-5
5-5
5-5
5-3
5-5
5-3
5-7
1-11
4-13
4-13
4-13
4-13
4-7
4-7
4-7
4-7
4-7
4-7
4-13
4-7
4-13
5-3
1-19
8-5
7-5
8-9
8-9
9-7

ITEM
9
8
11
18
11
6
12
6
6
17
3
14
12
27
18
41
27
7
23
7
3
1
11
26
4
1
1
16
27
15
10
19
17
1
29
10
2
4
8
1
15
32
5
10
15
4
21
11
14
7
16

PART NO. PG
1345204
1345216

1345264

1345348
1345412
1345413
1345423
1345573
1345576
1347004
1347314
1348185

1348187
1348246
1348247
1348459
1348464
1348469
1349446
1351681
1351682
1351683
1352806
1352808
1352809
1352813
1352908
1353006
1353008
1353009
1353013
1353191
1353192

8-9
9-7
7-2
7-7
7-15
8-2
9-2
8-13
8-17
8-25
9-9
9-19
7-5
7-5
7-5
9-7
9-7
9-7
4-7
4-13
4-13
7-15
8-25
9-19
8-29
8-9
8-9
7-7
7-7
7-7
1-17
2-15
2-15
2-17
8-13
8-13
8-13
8-13
9-9
8-17
8-17
8-17
8-17
8-17
9-19
7-2
7-7
7-9
7-15
8-13
8-25
9-2

ITEM
8
17
2
2
2
2
2
2
2
2
2
2
19
5
6
9
3
4
20
41
9
9
9
8
25
24
1
1
1
1
19
15
50
1
1
1
1
1
1
1
1
1
6
6
6
3
12
6
5
6
6

PART NO. PG

1353399
1353408

1353464
1353530

1353533
1353546
1353547
1353638
1353668
1354300
1354901
1354915

1354916

1354917

1354918
1354990
1355189
1355335
1355610
1356113
1356137
1356204
1356209
1358970
1359588
1360139
1360140
1360141
1360386

1360507

1360508
1360534
1360548

See Service Manual


for service procedures.

9-9
9-11
8-19
7-2
7-9
8-2
9-2
8-9
7-5
8-9
9-7
1-17
9-5
8-5
9-7
9-7
4-7
8-5
7-11
8-19
9-13
7-11
8-19
9-13
7-11
8-19
9-13
9-7
5-3
7-13
4-5
8-23
6-15
1-11
2-7
2-7
8-7
1-11
8-23
7-13
8-7
7-5
8-9
9-7
7-5
7-5
8-9
9-7
7-5
9-7
8-5
7-5

ITEM
3
17
16
8
17
8
8
23
3
29
5
2
11
11
22
23
3
21
21
10
9
21
10
9
21
10
9
10
5
16
3
4
31
30
16
5
4
20
17
17
17
14
22
8
18
20
30
7
2
6
20
9

PART NO. PG
1360549
1361302
1361372
1361373
1361374
1361376
1361377
1362527
1362528
1362529
1362531
1362532
1362557
1362558
1362559
1362561
1362562
1362702
1362703
1362704
1362706
1362713
1362715
1362716
1362717
1362719
1362721
1362722
1362723
1362725
1362726
1362732
1362745
1362746
1362749
1362756
1362871

1362875
1362880
1362881
1362886
1362888
1362889
1362894
1362923
1362925
1362926

7-5
8-9
8-7
7-13
7-13
7-13
7-13
7-13
7-13
7-13
7-13
7-13
7-13
7-13
7-13
7-13
7-13
7-13
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
8-23
7-13
8-23
9-17
8-23
9-15
8-7
8-7
8-7
8-7
9-5
8-7
8-7
8-7
8-7
8-7

ITEM
22
18
15
15
7
15
15
7
15
15
7
15
1
2
1
1
2

1
2
1
1
2
1
10
14
8
15
9
5
10

31

1
1
1

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

NUMERICAL INDEX (Continued)


PART NO. PG
1362931
1362960
1362962
1362963
1362968
1363250
1363251
1363253
1363256
1363260
1363261
1363272
1363306
1363308
1363309
1363313
1363486
1363886
1363916
1363917
1364271
1364281
1364542
1364588
1365061
1365140
1365308
1365504
1365516
1365607
1365637
1365666
1366057
1366725
1367645

1369333
1369345

1369357

8-7
8-7
8-7
8-7
8-7
8-19
8-19
8-9
8-9
8-29
8-29
8-2
8-15
8-5
8-5
8-5
8-5
7-5
2-17
1-19
1-19
4-13
5-3
5-7
1-13
10-15
10-19
9-7
8-19
9-5
9-7
9-7
9-15
9-17
9-17
9-15
8-23
1-11
10-3
10-11
10-17
10-19
8-9
9-7
7-2
7-9
8-2
8-15
9-2
9-11
7-11
8-5

ITEM
1
2
2
2
2
13
15
2
2
9
9
6
17
2
2
2
2
8
50
7
8
3
2
9
9
6
3
19
30
2
1
2
1
1
2
2
1
19
3
8
5
9
9
13
7
16
7
13
7
13
24
7

2004 HYSTER COMPANY

PART NO. PG

1369410
1369412
1371287
1371526
1371653
1371741
1371743
1371744
1371746
1374793
1374797

1374802
1375574

1376100

1376101

1376743
1377414
1378600
1378690
1378692
1378698

1378699

1378760
1378762
1378763
1378765
1379488
1379496
1379615
1379616
1379682
1379685

ITEM

8-19
9-5
2-16
2-16
8-29
8-29
7-13
8-23
6-11
6-11
6-11
6-11
2-7
7-2
7-9
8-2
8-15
9-2
9-11
9-15
7-5
8-9
9-7
7-11
8-19
9-13
7-11
8-19
9-13
4-13
5-5
4-13
9-5
9-5
7-7
8-5
8-17
7-7
8-5
8-17
9-5
1-15
1-15
1-15
1-15
4-13
8-5
9-5
10-15
10-15
9-5
7-7

27
7
37
30
6
11
4
3
2
5
4
13
21
3
13
3
20
3
20
8
21
31
21
26
21
20
26
22
20
31
13
18
30
8
25
11
9
24
12
29
8
7
6
9
45
17
17
4
5
27
7

PART NO.

1379687
1380035
1381082
1381095
1381598
1381599
1382130
1382302
1382305
1382311
1382312
1382313
1383195
1385099
1389343
1390575
1393132

1393142
1395285
1395291
1395292
1396406
1401746

1450503
1451696
1451697
1451698
1451703
1451707
1452459
1454478
1455770
1455771
1455773
1455776
1455779
1456085
1460539
1460672

See Service Manual


for service procedures.

PG
8-5
8-17
7-11
9-13
9-5
9-15
9-17
7-13
8-23
8-9
8-9
10-19
10-11
10-11
1-4
1-4
1-4
10-9
1-11
1-21
10-7
7-2
7-9
7-15
9-2
9-11
8-2
8-15
8-5
9-5
8-10
8-9
8-9
7-9
8-15
9-11
4-13
4-5
4-5
4-5
4-5
4-5
4-3
2-7
4-5
4-5
4-5
4-5
4-5
2-7
6-11
6-15

ITEM
22
10
11
11
24
4
4
3
10
12
13
1
13
14
66
67
68
1
16
18
8
6
12
6
6
17
6
17
8
8
33
32
10
9
9
9
34
4
6
8
13
23
1
11
7
9
16
21
22
3
13
20

PART NO. PG
1462468
1462527
1462528
1463139
1463194

1465784
1465787
1465792
1465793
1465794
1465795
1465796
1465797
1465800
1465801
1465813
1465814
1465817
1465818
1465819
1465820
1465821
1465822
1465823
1465824
1465825
1465826
1465827
1465828
1465829
1465834
1467390
1467391
1467392
1467424
1467425
1467426
1467428
1467430
1467529
1470152
1470153
1471618
1471650
1471658
1475250
1475399
1475400
1476421

4-5
4-13
4-9
4-9
2-17
2-15
2-15
2-16
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-9
4-5
4-5
4-5
4-5
4-5
4-5
4-5
4-5
1-21
1-21
1-21
1-11
4-9
4-10
5-5
4-10
4-10
10-11

ITEM
4
34
36
47
1
16
26
1
3
5
6
7
8
9
10
11
12
13
14
16
17
18
19
20
20
23
22
24
25
26
27
28
33
1
14
18
5
17
11
19
24
15
6
6
8
29
51
5
55
54
11
11-5

UNIT CODE J160


EUROPE

02/2004

NUMERICAL INDEX (Continued)


PART NO.

PG

1483422
1483828
1484397

1-4
1-21
2-15
2-15
2-15
2-16
5-3
5-3
7-9
8-15
9-11
7-16
7-16
7-16
7-16
10-12
8-5
9-5
2-15
2-15
2-16
2-15
2-15
2-16
4-7
2-15
2-15
2-17
2-15
7-5
8-9
4-9
8-27
4-9
4-9
4-9
4-9
4-9
4-10
4-9
4-9
4-9
4-9
4-9
4-10
3-9
3-9
4-10
9-15
9-17
9-15
9-17

1486737
1486770
1489010

1489016
1489035
1489037
1489039
1489050
1489972
1490242

1490243

1491830
1493430

1493465
1494017
1494373
1494719
1495388
1495389
1495390
1495391
1495392
1495393
1495394
1495395
1495397
1495398
1495399
1495400
1497280
1497282
1497558
1498115
1498116

11-6

ITEM
69
16
1
15
16
26
29
28
2
2
2
1
3
2
5
2
13
13
13
14
31
13
14
31
11
17
18
50
12
10
11
11
37
37
2
4
21
50
20
15
30
31
32
52
6
5
53
12
11
5
5

PART NO. PG
1498325
1498326

1498406
1500182
1500263
1500360
1500782
1502724
1502725
1502726
1502727
1502728
1502730
1502731
1502733
1502735
1502736
1503096
1503474
1503477
1503480
1503481
1504010

1505178
1508484
1510861
1510874
1514866

1518987
1519095
1520270
1520271
1520416
1520417
1520609

ITEM

7-16
7-9
8-15
9-11
4-7
6-17
2-7
2-7
1-15
6-17
6-17
6-17
6-17
6-17
6-17
6-17
6-17
6-17
6-17
7-16
10-12
10-12
10-12
10-12
7-2
7-9
8-2
8-15
9-2
9-11
10-15
4-9
6-9
4-13
7-2
7-9
7-11
8-2
8-5
8-15
8-19
9-2
9-5
9-11
10-11
1-4
4-13
4-13
6-13
6-15
6-21
4-13

4
21
21
21
16
11
1
9
4
1
2
3
4
5
7
8
10
12
13
7
2
1
1
1
7
16
7
13
7
13
2
42
38
38
10
19
22
10
5
15
28
10
5
15
3
62
22
28
6
6
6
25

PART NO. PG
1520731
1520733
1521321
1521399
1521400
1521401
1521402
1521403
1521404
1521405
1521406
1522424
1523614
1523615
1523623
1523732
1523733
1523734
1523877
1523879
1523880
1523995
1525348
1525349
1525351
1525750
1525751
1525760
1525767
1526082
1526274
1526275
1526276
1526650
1526656
1526744
1526869
1526871
1526872
1526877
1526883
1527262
1527296
1527297
1527299
1527304
1527326

See Service Manual


for service procedures.

4-13
4-13
1-3
4-9
4-9
4-9
4-10
4-10
4-10
1-3
1-3
5-3
1-3
1-3
1-3
1-15
1-15
1-15
8-29
8-29
8-29
4-18
1-4
1-4
1-4
1-3
1-3
2-11
2-9
10-19
7-2
8-2
9-2
1-3
6-15
6-13
8-25
8-25
9-19
7-15
8-25
7-15
8-25
7-15
1-3
1-3
1-4
1-3
1-4
1-3
1-4
1-4

ITEM

7
46
46
46
48
48
48
7
7
23
6
6
12
2
3
10
20
17
15
65
65
65
34
35
1
1
1
1
1
1
6
22
5
1
1
1
1
1
1
1
1
5
47
53
32
60
33
54
52

PART NO. PG
1527327
1527329
1527330
1527974
1528189
1528191
1528551
1528707
1528708
1528709
1528851
1528869
1529042
1529052

1529139
1529140
1529150
1529243
1529244
1529596
1529598
1529600
1530681
1530955
1531326
1532304
1532511
1532578
1532663
1532664
1533890
1533937
1534009
1534010
1534632
1534633
1534634
1534697
1536299
1538033
1538034
1538036
1538037
1538447
1539240
1539289
1539290
1539327
1539328
1539387

1-4
1-4
1-4
1-9
4-9
4-13
1-13
5-3
5-3
5-3
1-3
1-3
1-11
2-15
2-15
2-17
6-9
6-21
1-9
2-7
2-7
8-15
7-9
9-11
4-13
1-3
10-11
6-19
1-7
10-13
10-13
2-15
1-3
3-9
10-13
10-13
1-19
1-19
1-19
10-11
1-3
1-11
1-11
1-11
1-11
2-9
10-13
4-13
4-13
2-19
2-21
1-11

ITEM
49
59
55
4
44
40
8
24
25
26
1
27
23
17
18
50
2
2
1

1
1
1
39
18
7
4
11
1
2
15
19
21
2
6
6
6
6
20
4
5
21
22
1
3
21
34
1
1
28

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

NUMERICAL INDEX (Continued)


PART NO. PG
1539490
1539497
1539854
1540035
1540036
1540616
1541451
1541453
1541774
1541775
1541777
1541778
1541991
1541992
1542513
1542514
1542542
1544266
1544327
1544344
1544345
1544346
1544347
1544349
1544364
1544781

1545108
1545111
1545115
1545117
1545118
1545120
1545121
1545122
1545123
1545124
1545125
1545126
1545127
1545128
1545129
1545130
1545131
1545132
1545133
1545134
1545227
1545299
1545300

3-2
3-2
5-7
1-21
1-21
2-13
2-5
2-3
1-3
1-3
1-3
1-3
2-17
2-17
2-9
2-9
10-13
1-11
6-23
6-23
6-23
6-23
6-23
6-23
6-23
6-27
6-3
6-5
6-27
2-7
2-7
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-13
4-17
10-5
10-5

ITEM

8
1
1
1
1
28
29
30
31
47
47
1
1
4
17
3
4
5
6
8
2
11
3
11
25
11
9
13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
4
1
1

2004 HYSTER COMPANY

PART NO. PG
1545301
1545303
1545304
1545522
1546568
1546570
1546572
1546573
1546684
1546686
1547115
1547117
1547118
1547122
1547231
1547585
1547586
1547602
1547627
1547685
1548223
1548225
1548462
1548469
1548473
1548475
1550531
1551236
1551544
1551545
1551546
1551547
1553456
1553671

1553963
1554622
1554623
1554624
1554625
1554873
1554874
1554932
1555731
1555987
1556261

ITEM

10-5
10-5
10-5
4-17
6-5
6-5
6-5
6-5
6-3
6-27
6-3
6-27
8-9
8-9
8-9
8-9
6-9
6-25
6-25
2-16
2-7
2-13
6-15
6-15
5-7
5-7
5-7
5-7
1-13
1-13
6-25
6-25
6-25
6-25
1-3
6-7
6-7
6-7
6-7
1-19
6-25
6-25
1-4
1-4
10-11
10-17
10-11
1-19
6-7
6-7
2-19
5-9

PART NO.

PG

1
2
2
9
18
20
19
21
6
6
7
7
1
1
1
1
37
1
6
33
12
19
32
33
1

1556262
1556263
1556264
1556265
1556266
1556267
1556268
1556269
1556270
1556271
1556397
1556500
1556587

2
3
7
8
2
3
4
5
37
1
1
2
2
10
8
9
63
64
1
1
2
11
1
2
1
1

1557190

5-9
5-9
5-9
5-9
5-9
5-9
5-9
5-9
5-9
5-9
5-9
5-9
6-5
6-23
6-5
6-27
6-3
6-27
6-3
10-3
10-17
10-11
6-3
6-27
6-3
6-27
6-3
6-27
6-3
6-27
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-10
3-10

1556589
1556590
1556596
1557145
1557146
1557147
1557186
1557189

1557191
1557381
1557382
1557383
1557392
1557393
1557394
1557395
1557396
1557397
1557398
1557399
1557400
1557401
1557402
1557403
1557404
1557405
1557406
1557407
1557435
1557436
1557437

See Service Manual


for service procedures.

ITEM
2
3
4
5
6
7
8
9
10
11
12
13
22
1
23
1
2
2
3
2
4
4
5
5
8
8
9
9
10
10
1
2
41
40
3
7
8
4
9
10
11
12
42
42
42
13
14
15
16
17
43
44

PART NO. PG
1557438
1557439
1557440
1557441
1557442
1557443
1557444
1557445
1557446
1557447
1557448
1557449
1557450
1557451
1557452
1557454
1557455
1557467
1557470
1557471
1557472
1557474
1557475
1557480
1557699
1558094
1560099
1560101
1560157
1561561
1562665
1562666
1562874
1562878
1562879
1563192
1563193
1563207
1563208
1563209
1563210
1563211
1563212
1563215
1563218
1563222
1563230
1563231
1563350
1563351
1563353

3-10
3-10
3-10
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
3-9
6-25
6-3
6-5
1-4
1-4
1-11
3-9
1-21
1-21
2-7
2-7
2-7
1-21
1-21
1-21
1-21
1-21
1-21
1-21
1-21
1-21
1-21
1-21
1-21
1-21
1-21
1-21
1-21

ITEM
44
44
44
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
10
1
24
65
65
24
1
1
1
2
9
9
1
1
2
11
3
13
14
4
12
3
6
5
17
7
2
7
11-7

UNIT CODE J160


EUROPE

02/2004

NUMERICAL INDEX (Continued)


PART NO.

PG

1563712
1564043

6-13
2-3
2-5
2-21
2-19
2-21
6-17
6-17
3-7
3-7
3-7
3-7
3-7
3-7
3-7
7-5
7-5
7-5
4-9
9-7
2-16
8-7
8-7
6-9
6-21
1-11
1-7
1-7
1-7
1-7
1-11
1-11
2-3
4-3
4-17
4-3
4-3
4-9
1-19
1-19
2-17
2-7
2-7
2-15
2-15
2-15
2-16
2-16
2-16
2-7
3-2
3-2

1564205
1564241
1564327
1564328
1564559
1564560
1564561
1564562
1564592
1564593
1564594
1564626
1564631
1564636
2004005
2007554
2013089
2013099
2013239
2013578
2014599
2014600
2014602
2014603
2015059
2015060
2031026
2033614
2034265
2034266
2034281
2034347
2034348
2034482
2034484
2034488
2035275
2035276

2035396
2035601
2035605
11-8

ITEM
2
5
5
17
16
16
6
9
1
2
3
4
5
6
7
1
1
1
39
18
21
8
3
32
8
26
1
1
1
1
27
27
1
3
7
2
38
1
9
49
9
9
5
5
6
40
41
43
9
1
1

PART NO. PG
2036125
2036126
2036284
2037359
2037379
2037543
2037544
2037545
2042698
2043528

2043530

2043531

2043533

2043953
2044992

2044997
2044998

2045003
2045129
2046006
2046336
2046367
2047064
2047819

2047820

2048105
2049309
2049939
2050282
2052235
2053601
2053881
2053940
2053941

ITEM

3-2
3-2
10-15
10-7
1-3
2-16
2-17
2-17
6-19
7-9
7-16
8-15
9-11
7-9
8-15
9-11
7-9
8-15
9-11
7-9
8-15
9-11
2-16
2-15
2-15
2-16
2-16
2-15
2-15
2-16
2-16
4-13
6-25
9-17
9-15
8-27
2-15
2-16
2-17
2-15
2-16
2-16
2-17
4-17
2-17
1-11
8-27
6-11
5-3
5-11
1-7
1-7

2
2
3
6
23
32
51
48
3
3
3
3
6
6
6
4
4
4
5
5
5
29
4
11
27
32
4
11
27
32
2
7

PART NO. PG
2054280
2054598
2054599
2054600
2054601
2054602
2054827
2055493
2055494
2055495
2055624
2055625
2055751

2055756

2055758

2055834

2055836

2055837
9
8
28
46
8
25
28
46
1
54
2
4
7
1
17
17

2055841

2055885

2056115
2056243
2056244
2056352

See Service Manual


for service procedures.

6-19
8-27
8-29
8-27
8-29
8-27
8-29
8-27
8-27
4-18
8-2
9-2
7-2
2-19
2-21
7-7
7-11
7-15
7-7
7-11
7-15
7-7
7-11
7-15
8-5
8-13
8-17
8-19
8-25
8-5
8-13
8-17
8-19
8-25
8-5
8-13
8-17
8-19
8-25
8-5
8-13
8-17
8-19
8-25
9-5
9-9
9-19
1-4
2-16
2-15
2-16
2-15

ITEM

PART NO. PG

1
10

2056600
2056852

10
10
5
5
1

2056865
2056866
2056867
2056878

2056880
1
1

2059533
2059534
2059683
2060507
2060510
2060511
2060613
2060639
2060666
2061746
2061747
2061805
2061806
2061808
2061994
2061995
2062005
2062006
2062009
2062022
2062023
2062024
2062025
2062057

50
40
6
43

2062058
2062060
2062061
2062063

4-9
2-11
2-19
2-21
3-5
9-11
8-15
7-9
2-19
2-21
3-5
2-19
2-21
1-13
1-13
6-19
2-19
2-21
2-21
5-7
5-9
10-11
2-15
2-16
3-5
3-9
3-5
3-9
6-15
6-13
6-15
6-7
6-7
2-19
2-19
2-21
2-21
2-19
2-21
2-19
2-21
2-19
2-21
2-19
2-21
6-21
6-25
6-21
6-25
6-5
6-5
6-21

ITEM
45
3
12
12
7

8
8
6
10
10
12
13
2
22
23
24
16
10
7
44
1
2
1
1
5
1
2
7
5
6
5
14
14
15
15
17
18
18
19
22
22
1
1
4

2004 HYSTER COMPANY

UNIT CODE J160


EUROPE

02/2004

NUMERICAL INDEX (Continued)


PART NO. PG
2062064
2062067
2062068
2062072
2062264
2062265
2062266
2062267
2062350

2062351

2062360
2062361
2062560
2062718
2062742
2062743
2062822
2062823
2062824
2062825
2062827
2062871
2062873
2062875
2063091
2065094
2065095
2065362
2065363

6-9
6-5
6-5
6-21
1-13
1-13
1-13
1-13
2-19
2-21
3-5
2-19
2-21
3-5
2-19
2-21
2-19
2-21
1-13
1-13
5-3
2-11
6-15
6-15
6-15
6-15
6-13
2-16
2-16
1-4
3-5
3-7
6-7
6-7
6-9
6-9

ITEM
11
1
2
27
2
4
3
1
13
13
9
9
9
8
6
7
11
11
5
10
33
6
18
19
3
4
4
35
20
73
3

2004 HYSTER COMPANY

PART NO. PG
2065364
2065365
2065366
2065755
2066313
2066700
2066709
2066719
2066967
2067319
2067321
2067410
2068404
2068405
2068406
2068407
2068717
2068733
2068741

2068745
2068746
2068747
2068748
2068749

1
2
3
4

2068750
2068817

ITEM

6-9
6-9
6-17
6-15
2-15
10-3
1-13
2-11
5-3
4-17
10-11
10-17
4-14
1-11
1-11
1-11
1-11
6-15
6-19
2-15
2-15
2-16
2-16
2-16
2-16
6-13
6-15
6-13
6-15
6-13
6-15
6-13
6-15
6-13
2-11
2-21

5
6
15
10
1
11
4
16
5
2
46
29
29
18
18
2
13
5
6
40
41
43
34
12
12
11
11
14
14
13
13
3
5
25

PART NO.

PG

2068818

2-11
2-21
6-11
2-16
2-16
2-16
2-17
6-9
2-7
8-27
6-21
1-11
6-11
2-16
6-9
6-21
2-7
6-9
10-15
1-11
6-9
2-7
2-13
6-9
2-7
6-9
2-15
2-16
2-16
6-9
4-13
10-7
2-7
6-21
2-15
2-16

2069006
2069412
2069413
2069414
2069415
2302179
2302461
2302899
2303162
2303178
2303239
2303345
2303365
2303498
2303821
2303898
2303953
2304044
2304087
2304170
2304572
2304767
2305577
2305669
2305754

2306052
2306145
2306436
2307031
2307042
2307413

See Service Manual


for service procedures.

ITEM
5
26
30
38
41
52
20
4
1
15
12
1
36
14
9
7
30
1
13
28
8
20
27
15
17
9
39
45
12
23
7
10
14
8
28

PART NO. PG
2307513
2307542
2307638
2307659
2307799
2307803
2307900
2307965
2308059
2308118
2308174
2308915

2308995
2309196
2309317
2309362
2309570
2309579
2309978
2310972
2311380
2311384
2311392
2311444
2311598
2798897

2-16
6-9
1-7
6-13
6-15
8-27
1-3
1-7
2-7
6-21
1-7
6-9
2-16
8-27
2-15
2-15
2-16
2-3
2-5
5-7
1-13
1-7
6-9
2-17
6-9
1-3
6-9
2-16
6-21
6-9
8-27
1-3
6-5

ITEM
46
29
7
9
9
4
24
2
6
11
4
16
25
3
4
11
27
1
1
14
6
6
26
51
33
36
36
42
3
35
4
46
17

11-9

NOTES

11-10