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Hyster (a416) j2.00 xm parts catalogue manual
- 1. CUSTOMER EDITION PARTS MANUAL J2.00-3.20XM (A416) 1534742 ©2005 Hyster Company 09/2005
- 2. 09/2005 UNIT CODE A416 EUROPE SECTIONS 1 FRAME 2 ELECTRICAL SYSTEM 3 DRIVE UNIT 4 STEERING SYSTEM 5 BRAKE/ACCELERATOR SYSTEM 6 HYDRAULIC SYSTEM 7 MAST-TWO STAGE LIMITED FREE-LIFT 8 MAST-THREE STAGE FULL FREE-LIFT 9 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.
- 3. 09/2005 UNIT CODE A416 EUROPE TABLE OF CONTENTS DESCRIPTION PAGE A ACCELERATOR ................................................................................................................................................. 5-14 ACCELERATOR PEDAL MONOTROL ................................................................................................................................................... 5-16 AUDIBLE ALARMS ............................................................................................................................................ 10-8 B BRAKE ............................................................................................................................................................... 5-10 BRAKE AND BACK-UP LIGHTS........................................................................................................................ 10-2 BRAKE PEDAL LINKAGE .................................................................................................................................... 5-2 C CONTACTOR LINE................................................................................................................................................................ 2-28 POWER STEERING....................................................................................................................................... 2-30 CONTACTOR PANEL CONTACTOR AND TRANSISTOR HYDRAULIC............................................................................................ 2-26 CONTACTOR HYDRAULIC ............................................................................................................................ 2-32 CONTROL PANEL CONTACTOR HYDRAULIC GEN IV ⇒S/N A416A02448C............................................................................................................................... 2-18 GEN V S/N A416A02449C⇒............................................................................................................................... 2-22 TRANSISTOR HYDRAULIC GEN IV ⇒S/N A416A02448C............................................................................................................................... 2-12 GEN V S/N A416A02449C⇒............................................................................................................................... 2-16 CONTROL VALVE FOUR FUNCTION .......................................................................................................................................... 6-28 THREE FUNCTION ........................................................................................................................................ 6-24 CONTROL VALVE ATTACHING PARTS............................................................................................................. 6-22 COUNTERWEIGHT ........................................................................................................................................... 1-12 COVERS .............................................................................................................................................................. 1-6 D DASH DISPLAY.................................................................................................................................................. 2-10 DC CONVERTER............................................................................................................................................. 10-11 DRIVE AND REAR LIGHTS............................................................................................................................... 10-4 DRIVE AXLE ........................................................................................................................................................ 3-2 DRIVE MOTOR MOUNT ...................................................................................................................................... 6-6 DRIVE TIRE AND WHEEL STANDARD PNEUMATIC............................................................................................................................... 3-14 DRIVE WHEEL AND TIRE PNEUMATIC RADIAL ..................................................................................................................................... 3-15 E ELECTRICAL GEN IV ⇒S/N A416A02448C .................................................................................................................................... 2-2 ©2005 HYSTER COMPANY i See Service Manual for service procedures.
- 4. UNIT CODE A416 EUROPE 09/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE E (continued) GEN V S/N A416A02449C⇒ .................................................................................................................................... 2-6 F FORKS ............................................................................................................................................................... 1-22 FRAME................................................................................................................................................................. 1-4 FREE LIFT CYLINDER TWO STAGE FULL FREE-LIFT...................................................................................................................... 9-16 FREE-LIFT THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-12 TWO STAGE FULL FREE-LIFT........................................................................................................................ 9-8 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-20 FULL SUSPENSION SEAT SHEET 1 OF 2................................................................................................................................................ 1-14 SHEET 2 OF 2................................................................................................................................................ 1-16 G GEAR PUMP...................................................................................................................................................... 4-14 OPTIONAL...................................................................................................................................................... 4-16 GENERAL TRUCK ............................................................................................................................................... 1-2 H HAND LEVER..................................................................................................................................................... 6-18 HEADER HOSE THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-26 TWO STAGE FULL FREE-LIFT...................................................................................................................... 9-20 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-16 HOOD................................................................................................................................................................... 1-8 HYDRAULIC......................................................................................................................................................... 6-2 HYDRAULIC PUMP 19 CC PUMP - LOW NOISE OPTIONAL .................................................................................................................................................. 6-10 19 CC SINGLE GEAR PUMP........................................................................................................................... 6-8 HYDRAULIC PUMP MOTOR 72/80 VOLT A/C IDENTIFY BY PART NUMBER ⇒D/B 06/2004 ......................................................................................................................................... 6-12 72/80 VOLT D/C.............................................................................................................................................. 6-16 IDENTIFY BY PART NUMBER D/B 06/2004⇒............................................................................................................................................. 6-14 HYDRAULIC TANK............................................................................................................................................... 6-4 I INNER MAST THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-6 TWO STAGE FULL FREE-LIFT........................................................................................................................ 9-4 TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-4 INTEGRAL SIDE-SHIFT CARRIAGE ii ©2005 HYSTER COMPANY See Service Manual for service procedures.
- 5. 09/2005 UNIT CODE A416 EUROPE TABLE OF CONTENTS (Continued) DESCRIPTION PAGE I (continued) THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-14 TWO STAGE FULL FREE-LIFT.................................................................................................................... 10-16 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 10-12 INTEGRAL SIDE-SHIFT CYLINDER ............................................................................................................... 10-18 INTEGRAL SIDE-SHIFT HYDRAULIC HOSES TWO AND THREE STAGE FULL FREE-LIFT .............................................................................................. 10-21 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 10-20 INTERFACE CABLE......................................................................................................................................... 10-10 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-4 L LABELS AND DECALS...................................................................................................................................... 1-18 LIFT TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6 LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT J2.00XM-J2.50XM......................................................................................................................................... 7-9 J3.00XM-J3.20XM....................................................................................................................................... 7-11 LOAD BACKREST EXTENSION........................................................................................................................ 1-20 M MAIN CYLINDER THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-16 TWO STAGE FULL FREE-LIFT LEFT HAND ................................................................................................................................................ 9-11 RIGHT HAND.............................................................................................................................................. 9-13 MAIN LIFT THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-8 TWO STAGE FULL FREE-LIFT........................................................................................................................ 9-6 MAST INSTALLATION........................................................................................................................................ 6-32 MASTER CYLINDER ........................................................................................................................................... 5-8 O OUTER MAST THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-2 TWO STAGE FULL FREE-LIFT........................................................................................................................ 9-2 TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-2 OVERHEAD GUARD.......................................................................................................................................... 1-10 P PARK BRAKE LEVER ACTUATED ...................................................................................................................... 5-4 S SHIFT LEVER ...................................................................................................................................................... 4-4 SIX ROLLER CARRIAGE THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-24 TWO STAGE FULL FREE-LIFT...................................................................................................................... 9-18 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-14 ©2005 HYSTER COMPANY iii See Service Manual for service procedures.
- 6. UNIT CODE A416 EUROPE 09/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE S (continued) STEERING AXLE............................................................................................................................................... 4-18 STEERING CONTROL UNIT ............................................................................................................................... 4-6 STEERING CYLINDER PENDING PER ECN 10403001⇒.................................................................................................................. 4-12 ⇒PENDING PER ECN 10403001.................................................................................................................. 4-10 STEERING HYDRAULIC...................................................................................................................................... 4-8 STEERING POD .................................................................................................................................................. 4-2 STEERING WHEEL AND TIRE STANDARD PNEUMATIC............................................................................................................................... 4-20 STROBE LIGHT ................................................................................................................................................. 10-6 T TILT CYLINDER ................................................................................................................................................. 6-34 TRACTION MOTOR A/C IDENTIFY BY PART NUMBER ⇒D/B 05/2004 ......................................................................................................................................... 3-10 IDENTIFY BY PART NUMBER D/B 06/2004⇒............................................................................................................................................. 3-12 TRANSMISSION AND DIFFERENTIAL............................................................................................................... 3-6 W WIRE HARNESS FORWARD/REVERSE LEVER....................................................................................................................... 2-41 LIGHTS........................................................................................................................................................... 2-42 MAIN GEN IV ⇒S/N A416A02448C............................................................................................................................... 2-34 WIRE HARNESS (MAIN) GEN V SHEET 1 0F 2 S/N A416A02449C⇒............................................................................................................................... 2-36 SHEET 2 OF 2 S/N A416A02449C⇒............................................................................................................................... 2-38 iv ©2005 HYSTER COMPANY See Service Manual for service procedures.
- 7. 09/2005 UNIT CODE A416 EUROPE ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: TERM DEFINITION Amp Amperes AR As Required BDI Battery Discharge Indicators BWI Brush Wear Indicator CE Communicator End CRE Corrosive Environment D/B Date Break dbA Decibel "A" Scale DE Drive End ECH Empty Container Handler ECH-3 Empty Container Handler - 3 High Stacking ECH-4 Empty Container Handler - 4 High Stacking ECH-5 Empty Container Handler - 5 High Stacking ECH-6 Empty Container Handler - 6 High Stacking ECH-7 Empty Container Handler - 7 High Stacking ECM Electronic Control Module ECN Engineering Change Notice EEPROM Electrically Erasable Programmable Read Only Memory EPA US Environmental Protection Agency EPROM Electrically Programmable Read Only Memory TERM DEFINITION FRE Freezer Environment in. inches LPG Liquefied Petroleum Gas MAP Manifold Absolute Pressure mm millimeters MSTS Microprocessor Spark Timing System NPT National Pipe Threads O/S Oversize PTO Power Take Off RPM Revolutions per Minute S/N Serial Number TMM Truck Management Module UL Type D Diesel-Powered Safety Rating UL Type DS Diesel-Powered Safety Rating UL Type E Battery-Powered Safety Rating UL Type EE Battery-Powered Safety Rating UL Type ES Battery-Powered Safety Rating UL Type G Gasoline-Powered Safety Rating UL Type GS Gasoline-Powered Safety Rating UL Type LP Gas-Powered Safety Rating UL Type LPS LP Gas-Powered Safety Rating U/S Undersize UL Underwriters Laboratory V Volts ©2005 HYSTER COMPANY v See Service Manual for service procedures.
- 8. UNIT CODE A416 EUROPE 09/2005 HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement. The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page. vi ©2005 HYSTER COMPANY See Service Manual for service procedures.
- 9. 09/2005 UNIT CODE A416 EUROPE HOW TO FIND THE DESIRED PART NUMBER WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: 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. 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. 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 previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE. 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. 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. 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. ©2005 HYSTER COMPANY vii See Service Manual for service procedures.
- 10. UNIT CODE A416 EUROPE 09/2005 IDENTIFICATION OF TRUCK SERIAL NUMBERS (1) and (2) The first letter and three numbers indicate the truck unit code. (3) The second letter indicates the plant of manufacture. (4) The four or five digit number indicates the production sequence number of the truck. (5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003. The letters "I", "O", and "Q" will not be used. For pending serial numbers contact your local dealer for Hyster lift trucks. Parts referred to in this book as right or left hand parts are in accordance with the illustration above. viii ©2005 HYSTER COMPANY See Service Manual for service procedures.
- 11. 09/2005 UNIT CODE A416 EUROPE IDENTIFICATION OF MAST SERIAL NUMBERS (1) and (2) The first letter and number indicates the mast unit code. (3) The second letter indicates the plant of manufacture. (4) The four or five digit number indicates the production sequence number of the mast. (5) Carriage travel in millimeters stamped just below the serial number. Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5). For pending production sequence numbers contact your local dealer for Hyster lift trucks. LIFT EQUIPMENT IDENTIFICATION 1. Fork part number, capacity rating, plant code letter, and date of manufacture are stamped approximately six inches below the top of most forks. 2. The carriage group number is stamped on the right hand side of the top crossmember (pin type) or on the back of the right hand end of the bottom crossmember (hook type). A date code has two letters in line with or below the carriage group number. 3. The mast identification number has a unit code, a letter indicating the plant of manufacture, and a serial number. Underneath the production sequence number is a four digit number that indicates the carriage travel in millimeters. 4. Tilt and lift cylinder group numbers are stamped on the cylinder shell. Always refer to the group, serial, or part number when ordering service parts. Modification of masts and carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". contact your dealer for Hyster lift trucks for information on these assemblies. ©2005 HYSTER COMPANY ix See Service Manual for service procedures.
- 12. UNIT CODE A416 EUROPE 09/2005 IDENTIFICATION OF ATTACHMENT AND SIDE-SHIFT CARRIAGE SERIAL NUMBERS (1) and (2) The first letter and three numbers indicate the attachment unit code. (3) The second letter indicates the plant of manufacture. (4) The four or five digit number indicates the production sequence number. For pending production sequence numbers contact your local dealer for Hyster lift trucks. Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify the attachment. Always refer to the group, serial, or part number when ordering service parts. Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". Contact your dealer for Hyster lift trucks for information on these assemblies. x ©2005 HYSTER COMPANY See Service Manual for service procedures.
- 13. 09/2005 UNIT CODE A416 EUROPE 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 .................................................................................................................. 1534741 Service Manual (Complete) .................................................................................................. 1534731 Parts Manual .......................................................................................................................... 1534742 ©2005 HYSTER COMPANY xi See Service Manual for service procedures.
- 14. NOTES xii
- 15. 09/2005 UNIT CODE A416 EUROPE 1 FRAME 1 FRAME
- 16. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
- 17. 09/2005 UNIT CODE A416 EUROPE SECTION 1 FRAME DESCRIPTION PAGE COUNTERWEIGHT ........................................................................................................................................... 1-12 COVERS .............................................................................................................................................................. 1-6 FORKS ............................................................................................................................................................... 1-22 FRAME................................................................................................................................................................. 1-4 FULL SUSPENSION SEAT SHEET 1 OF 2................................................................................................................................................ 1-14 SHEET 2 OF 2................................................................................................................................................ 1-16 GENERAL TRUCK ............................................................................................................................................... 1-2 HOOD................................................................................................................................................................... 1-8 LABELS AND DECALS...................................................................................................................................... 1-18 LOAD BACKREST EXTENSION........................................................................................................................ 1-20 OVERHEAD GUARD.......................................................................................................................................... 1-10 ©2005 HYSTER COMPANY 1-1 See Service Manual for service procedures.
- 18. UNIT CODE A416 EUROPE 09/2005 GENERAL TRUCK (Figure 1-1) 1-2 ©2005 HYSTER COMPANY See Service Manual for service procedures.
- 19. 09/2005 UNIT CODE A416 EUROPE GENERAL TRUCK ITEM PART NO. DESCRIPTION QTY 1 . . . . . Frame (☞ Figure 1-2) ................................................................................................ .. 2 . . . . . Electrical System (☞ Figure 2-1) ............................................................................... .. 3 . . . . . Drive Unit (☞ Figure 3-1) ........................................................................................... .. 4 . . . . . Steering System (☞ Figure 4-1) ................................................................................ .. 5 . . . . . Brake and Accelerator (☞ Figure 5-1) ....................................................................... .. 6 . . . . . Hydraulic System (☞ Figure 6-1) ............................................................................... .. 7 . . . . . Mast-Two Stage Limited Free-Lift (☞ Figure 7-1) ...................................................... .. 8 . . . . . Mast-Two Stage Full Free-Lift (☞ Figure 9-1) ............................................................ .. 9 . . . . . Mast-Three Stage Full Free-Lift (☞ Figure 8-1) ......................................................... .. 10 . . . . . Optional Equipment (☞ Figure 10-1) ......................................................................... .. ©2005 HYSTER COMPANY 1-3 See Service Manual for service procedures.
- 20. UNIT CODE A416 EUROPE 09/2005 FRAME (Figure 1-2) 1-4 ©2005 HYSTER COMPANY See Service Manual for service procedures.
- 21. 09/2005 UNIT CODE A416 EUROPE FRAME ITEM PART NO. DESCRIPTION QTY 1 1461197 Cowl............................................................................................................................. 1 2 17105 Bolt .............................................................................................................................. 2 3 15156 Lockwasher.................................................................................................................. 2 4 221767 Washer ........................................................................................................................ 4 5 15056 Nut ............................................................................................................................... 2 6 136692 Nut ............................................................................................................................... 12 7 320160 Washer ........................................................................................................................ 16 8 292682 Lockwasher.................................................................................................................. 12 9 18494 Capscrew..................................................................................................................... 1 10 1385122 Floorplate..................................................................................................................... 1 10 878220 Floormat ...................................................................................................................... 1 11 1380562 Floorplate..................................................................................................................... 1 12 1350231 Plug ............................................................................................................................. 2 13 292519 Capscrew..................................................................................................................... 2 14 292681 Lockwasher.................................................................................................................. 2 15 296421 Washer ........................................................................................................................ 2 16 239503 Nut ............................................................................................................................... 2 17 a 1364498 Step (717 mm Battery Compartment) (LH) ................................................................. 1 17 a 1364499 Step (861 mm Battery Compartment) (LH) ................................................................. 1 17 b 1364552 Step (717 mm Battery Compartment) (LH) ................................................................. 1 17 b 1364553 Step (861 mm Batery Compartment) (LH) .................................................................. 1 18 a 1364555 Step (717 mm Battery Compartment) (RH)................................................................. 1 18 a 1364556 Step (861 mm Battery Compartment) (RH)................................................................. 1 18 b 1364557 Step (717 mm Battery Compartment) (RH)................................................................. 1 18 b 1364558 Step (861 mm Battery Compartment) (RH)................................................................. 1 19 1378906 Plate ............................................................................................................................ 2 20 316678 Screw........................................................................................................................... 6 21 1377420 Rod .............................................................................................................................. 1 22 1377421 Pin ............................................................................................................................... 1 23 1380449 Knob ............................................................................................................................ 1 24 296128 Nut ............................................................................................................................... 1 25 264134 Sealant ........................................................................................................................ AR 26 1379304 Plate ............................................................................................................................ 1 27 1379324 Capscrew..................................................................................................................... 1 28 296136 Nut ............................................................................................................................... 2 29 296227 Capscrew..................................................................................................................... 2 30 169874 Nut ............................................................................................................................... 1 FOOTNOTES: a Standard Tread b Wide Tread ©2005 HYSTER COMPANY 1-5 See Service Manual for service procedures.
- 22. UNIT CODE A416 EUROPE 09/2005 COVERS (Figure 1-3) 1-6 ©2005 HYSTER COMPANY See Service Manual for service procedures.