2014 Hyster E4.0XN E5.0XN E5.0XNS E5.5XN (A099) Parts Manual – PDF DOWNLOAD
DESCRIPTION:
2014 Hyster E4.0XN E5.0XN E5.0XNS E5.5XN (A099) Parts Manual – PDF DOWNLOAD
HOW TO USE THE ILLUSTRATED PARTS MANUAL :
- This parts manual describes and illustrates assemblies, sub-assemblies, and detail parts needed for service replacement.
- The different constructions are indicated by keys and footnotes. The call outs correspond to descriptions found on the next page.
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.
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 (Page i).
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 12-1) 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. Parts Super session Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.
- 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)
TABLE OF CONTENTS:
2014 Hyster E4.0XN E5.0XN E5.0XNS E5.5XN (A099) Parts Manual – PDF DOWNLOAD
Frame……………………………………………………………………………………………… 19
OPERATOR MODULE…………………………………………………………………………………. 22
COUNTERWEIGHT…………………………………………………………………………………… 24
COUNTERWEIGHT COVER WITH RAPID CHARGE OPTION……………………………………………………….. 25
OVERHEAD GUARD………………………………………………………………………………….. 26
FLOORPLATES AND STEPS……………………………………………………………………………. 28
HOOD WITH STANDARD OVERHEAD GUARD – E4.0-5.5XN …………………………………………………….. 30
HOOD WITH STANDARD OVERHEAD GUARD – E5.0XNS ……………………………………………………….. 32
FULL SUSPENSION SEAT MANUAL HYDRAULIC – SHEET 1 OF 2 ……………………………………………….. 34
FULL SUSPENSION SEAT MANUAL HYDRAULIC – SHEET 2 OF 2 ……………………………………………….. 38
FULL SUSPENSION SEAT ELECTRO HYDRAULIC – SHEET 1 OF 2 ………………………………………………. 40
FULL SUSPENSION SEAT ELECTRO-HYDRAULIC – SHEET 2 OF 2 ………………………………………………. 44
ARMREST SLIDER ASSEMBLY………………………………………………………………………….. 46
BATTERY COMPARTMENT AND COVERS HORIZONTAL BATTERY REMOVAL (→ 4/2013) ………………………………… 48
BATTERY COMPARTMENT AND COVERS HORIZONTAL BATTERY REMOVAL (4/2013 →) ………………………………… 52
BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL – E4.0-5.5XN (→ 4/2013) ……………………… 56
BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL – E4.0-5.5XN (4/2013 →) ……………………… 58
BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL – E5.0XNS ……………………………………. 60
DASH AND STEERING COLUMN COVERS FIXED COLUMN……………………………………………………….. 62
DASH AND STEERING COLUMN COVERS TELESCOPIC COLUMN…………………………………………………… 64
FENDERS………………………………………………………………………………………… 66
FORKS STANDARD TAPER CLASS III AND CLASS IV………………………………………………………… 67
FORKS STANDARD TAPER OPTIONAL – CLASS III AND CLASS IV ……………………………………………… 69
LOAD BACKREST EXTENSION………………………………………………………………………….. 72
NAMEPLATES AND LABELS SHEET 1 OF 2………………………………………………………………… 74
NAMEPLATES AND LABELS SHEET 2 OF 2………………………………………………………………… 76
NAMEPLATES AND LABELS HYDRAULIC CONTROL FUNCTIONS…………………………………………………… 78
ELECTRICAL SYSTEM…………………………………………………………………………………… 81
ELECTRICAL ARRANGEMENT…………………………………………………………………………… 86
BATTERY CONNECTOR WITH STANDARD OVERHEAD GUARD – E4.0-5.5XN …………………………………………. 88
BATTERY CONNECTOR WITH STANDARD OVERHEAD GUARD – E5.0XNS ……………………………………………. 89
BATTERY CONNECTOR WITH FLAT OVERHEAD GUARD…………………………………………………………. 90
CONTROL PANELS AND CONTACTORS…………………………………………………………………….. 91
CONTACTOR AND FUSE ASSEMBLY………………………………………………………………………. 92
CONTACTOR ASSEMBLY UL-E………………………………………………………………………….. 93
CONTROLLER ASSEMBLY PUMP MOTOR……………………………………………………………………. 94
CONTROLLER ASSEMBLY TRACTION MOTOR………………………………………………………………… 96
DISPLAY GROUP AND HARNESS………………………………………………………………………… 98
LIGHTS………………………………………………………………………………………….100
MINI-LEVER CONTROLS 3 FUNCTION…………………………………………………………………….104
MINI-LEVER CONTROLS 4 FUNCTION…………………………………………………………………….106
POWER CABLES E4.0-5.5XN…………………………………………………………………………..108
POWER CABLES E5.0XNS……………………………………………………………………………..110
TILT SENSOR GROUP………………………………………………………………………………..112
TURN SIGNAL……………………………………………………………………………………..113
VEHICLE SYSTEM MANAGER……………………………………………………………………………114
WIRE HARNESS RH LIGHT WITH STANDARD DISPLAY (→ 10/2013) …………………………………………….115
WIRE HARNESS RH LIGHT WITH STANDARD DISPLAY (10/2013 →) …………………………………………….116
WIRE HARNESS RH LIGHT WITH FREEZER DISPLAY (→ 10/2013) ……………………………………………..118
WIRE HARNESS RH LIGHT WITH FREEZER DISPLAY (10/2013 →) ……………………………………………..120
WIRE HARNESS EMERGENCY DISCONNECT………………………………………………………………….121
WIRE HARNESS FRONT SWITCH…………………………………………………………………………122
WIRE HARNESS LIGHTS – LEFT HAND W/O TURN SIGNALS ……………………………………………………124
WIRE HARNESS LIGHTS – LEFT HAND W/TURN SIGNALS ……………………………………………………..126
WIRE HARNESS MAIN – MANUAL-HYDRAULIC SHEET 1 OF 3 …………………………………………………..128
WIRE HARNESS MAIN – MANUAL-HYDRAULIC SHEET 2 OF 3 …………………………………………………..132
WIRE HARNESS MAIN – MANUAL-HYDRAULIC SHEET 3 OF 3 …………………………………………………..136
WIRE HARNESS MAIN – ELECTRO-HYDRAULIC SHEET 1 OF 3 ………………………………………………….140
WIRE HARNESS MAIN – ELECTRO-HYDRAULIC SHEET 2 OF 3 ………………………………………………….144
WIRE HARNESS MAIN – ELECTRO-HYDRAULIC SHEET 3 OF 3 ………………………………………………….148
WIRE HARNESS MAIN LIGHTS CHASSIS – 80V …………………………………………………………….152
WIRE HARNESS MANUAL INTERLOCK……………………………………………………………………..155
WIRE HARNESS SEAT – E-HYDRAULIC …………………………………………………………………..156
WIRE HARNESS SEAT – E-HYDRAULIC WITH SEAT BELT SEQUENCE MODULE ……………………………………….158
WIRE HARNESS SEAT – MANUAL HYDRAULIC ………………………………………………………………159
WIRE HARNESS SEAT – MANUAL HYDRAULIC WITH SEAT BELT SEQUENCE MODULE …………………………………..160
WIRE HARNESS STEERING COLUMN………………………………………………………………………162
WIRE HARNESS SYNCHRONOUS STEERING………………………………………………………………….164
WIRE HARNESS TURN SIGNAL SWITCH……………………………………………………………………166
WIRE HARNESS TURN SIGNAL………………………………………………………………………….168
WIRE HARNESS JUMPER………………………………………………………………………………170
WIRE HARNESS LEFT HAND – WITHOUT TURN SIGNALS (10/2013 →) ………………………………………….172
WIRE HARNESS LEFT HAND – WITH TURN SIGNALS (10/2013 →) …………………………………………….174
DRIVE UNIT………………………………………………………………………………………….177
DRIVE AXLE AND ATTACHING PARTS…………………………………………………………………….180
DRIVE AXLE ASSEMBLY WET BRAKE – RIGHT AND LEFT HAND HUBS …………………………………………….182
DRIVE AXLE ASSEMBLY WET BRAKE – BRAKES AND DIFFERENTIAL ……………………………………………..186
DRIVE AXLE ASSEMBLY WET BRAKE – INPUT PINION CARRIER ………………………………………………..189
DIFFERENTIAL ASSEMBLY WET BRAKE……………………………………………………………………191
TRACTION MOTOR…………………………………………………………………………………..192
DRIVE TIRE AND WHEEL E4.0XN……………………………………………………………………….193
DRIVE TIRE AND WHEEL E5.0-5.5XN/E5.0XNS…………………………………………………………….194
STEERING SYSTEM……………………………………………………………………………………..195
STEER COLUMN FIXED……………………………………………………………………………….198
STEER COLUMN TELESCOPIC…………………………………………………………………………..200
STEER PUMP ASSEMBLY………………………………………………………………………………202
STEER AXLE WITHOUT SYNCHRONUS STEERING OPTION……………………………………………………….204
STEER AXLE WITH SYNCHRONUS STEERING OPTION………………………………………………………….208
STEER AXLE CYLINDER………………………………………………………………………………212
STEERING ACCUMULATOR……………………………………………………………………………..214
STEER TIRE AND WHEEL……………………………………………………………………………..215
STEERING WHEEL AND COLUMN FIXED……………………………………………………………………216
STEERING WHEEL AND COLUMN TELESCOPIC……………………………………………………………….217
STEERING COLUMN ASSEMBLY FIXED (→ 10/2013) ………………………………………………………..218
STEERING COLUMN ASSEMBLY FIXED (10/2013 →) ………………………………………………………..220
STEERING COLUMN ASSEMBLY TELESCOPIC (→ 10/2013) ……………………………………………………222
STEERING COLUMN ASSEMBLY TELESCOPIC (10/2013 →) ……………………………………………………223
BRAKE/ACCELERATOR SYSTEM……………………………………………………………………………..225
BRAKE SYSTEM…………………………………………………………………………………….228
BRAKE ASSEMBLY…………………………………………………………………………………..230
PARKING BRAKE VALVE………………………………………………………………………………232
MASTER CYLINDER………………………………………………………………………………….233
ACCELERATOR PEDAL ASSEMBLY (STANDARD)………………………………………………………………234
ACCELERATOR PEDAL ASSEMBLY (MONOTROL)………………………………………………………………235
HYDRAULIC SYSTEM…………………………………………………………………………………….237
HYDRAULIC SUPPLY AND RETURN……………………………………………………………………….240
HYDRAULIC TANK AND ATTACHING PARTS…………………………………………………………………244
HYDRAULIC HOSES STEERING………………………………………………………………………….246
HYDRAULIC PUMP AND MOTOR MOUNTING…………………………………………………………………248
HYDRAULIC PUMP 33 cc……………………………………………………………………………..250
HYDRAULIC MOTOR ASSEMBLY………………………………………………………………………….252
MANUAL CONTROL LEVERS…………………………………………………………………………….254
HYDRAULIC CONTROL VALVE AND FITTINGS MANUAL HYDRAULIC – THREE AND FOUR FUNCTION ………………………..257
HYDRAULIC CONTROL VALVE ASSEMBLY MANUAL HYDRAULIC – THREE AND FOUR FUNCTION ……………………………258
HYDRAULIC CONTROL VALVE LIFT, TILT, AND AUXILIARY – MANUAL HYDRAULIC ………………………………….260
HYDRAULIC CONTROL VALVE INLET SECTION – MANUAL HYDRAULIC …………………………………………….262
HYDRAULIC CONTROL VALVE AND FITTINGS ELECTRO-HYDRAULIC – THREE AND FOUR FUNCTION ……………………….264
HYDRAULIC CONTROL VALVE ASSEMBLY ELECTRO-HYDRAULIC – THREE AND FOUR FUNCTION …………………………..266
HYDRAULIC CONTROL VALVE LIFT, TILT, AND AUXILIARY – ELECTRO-HYDRAULIC …………………………………268
HYDRAULIC CONTROL VALVE INLET SECTION – ELECTRO-HYDRAULIC ……………………………………………270
TILT CYLINDER AND ATTACHING PARTS………………………………………………………………….272
TILT CYLINDER……………………………………………………………………………………274
Mast-Two Stage Limited Free-Lift………………………………………………………………………277
OUTER MAST TWO STAGE LIMITED FREE-LIFT……………………………………………………………..280
INNER MAST TWO STAGE LIMITED FREE-LIFT……………………………………………………………..284
MAIN LIFT TWO STAGE LIMITED FREE-LIFT (→ PENDING PER ECN 15482601) …………………………………..288
MAIN LIFT TWO STAGE LIMITED FREE-LIFT (PENDING PER ECN 15482601 →) …………………………………..292
MAIN LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT – E4.0XN ……………………………………………..296
MAIN LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT – E5.0-5.5XN/E5.0XNS …………………………………..298
CARRIAGE TWO STAGE LIMITED FREE-LIFT……………………………………………………………….302
HEADER HOSE TWO STAGE LIMITED FREE-LIFT…………………………………………………………….304
INTEGRAL SIDE-SHIFT TWO STAGE LIMITED FREE LIFT CLASS IV – ORFS FITTINGS ………………………………310
Mast-Three Stage Full Free-Lift……………………………………………………………………….313
OUTER MAST THREE STAGE FULL FREE-LIFT (→ PENDING PER ECN 15482601) …………………………………..316
OUTER MAST THREE STAGE FULL FREE-LIFT (PENDING PER ECN 15482601 →) …………………………………..320
INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT………………………………………………………..324
INNER MAST THREE STAGE FULL FREE-LIFT………………………………………………………………328
MAIN LIFT THREE STAGE FULL FREE-LIFT……………………………………………………………….330
MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT……………………………………………………….334
FREE-LIFT THREE STAGE FULL FREE-LIFT (→ PENDING PER ECN 15482601) ……………………………………338
FREE-LIFT THREE STAGE FULL FREE-LIFT (PENDING PER ECN 15482601 →) ……………………………………342
FREE-LIFT CYLINDER THREE STAGE FULL FREE LIFT……………………………………………………….346
CARRIAGE THREE STAGE FULL FREE-LIFT………………………………………………………………..350
HEADER HOSE THREE STAGE FULL FREE-LIFT……………………………………………………………..352
Mast-Two Stage Full Free-Lift…………………………………………………………………………357
OUTER MAST AND MAIN LIFT TWO STAGE FULL FREE-LIFT……………………………………………………360
INNER MAST AND FREE-LIFT TWO STAGE FULL FREE-LIFT (→ PENDING PER ECN 15482601) ………………………..364
INNER MAST AND FREE-LIFT TWO STAGE FULL FREE-LIFT (PENDING PER ECN 15482601 →) ………………………..368
MAIN LIFT CYLINDER TWO STAGE FULL FREE-LIFT…………………………………………………………372
FREE-LIFT CYLINDER TWO STAGE FULL FREE-LIFT…………………………………………………………376
CARRIAGE TWO STAGE FULL FREE-LIFT………………………………………………………………….380
HEADER HOSE TWO STAGE FULL FREE-LIFT……………………………………………………………….382
OPTIONS…………………………………………………………………………………………….389
ACCUMULATOR……………………………………………………………………………………..392
BACK-UP ALARM……………………………………………………………………………………394
TAIL LIGHT MOUNTING………………………………………………………………………………395
MIRRORS…………………………………………………………………………………………396
MIRROR PANORAMIC…………………………………………………………………………………397
FIRE EXTINGUISHER………………………………………………………………………………..398
REAR DRIVE HANDLE………………………………………………………………………………..399
IMPACT SENSOR……………………………………………………………………………………400
DC CONVERTER AND ATTACHING PARTS…………………………………………………………………..402
INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE LIMITED FREE LIFT CLASS III – ORFS FITTINGS ……………………..404
INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE LIMITED FREE LIFT CLASS IV – ORFS FITTINGS ………………………406
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT – 1067 MM (42 IN.) CLASS III …………………..408
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT – 1219 MM (48 IN.) CLASS III …………………..410
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT – 1219 MM (48 IN.) CLASS IV ……………………412
INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE FULL FREE-LIFT – E4.0XN ……………………………………….414
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT – 1067 MM (42 IN.) CLASS III ……………………..416
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS III ……………………..418
INTEGRAL SIDE-SHIFT THREE STAGE FULL FREE-LIFT – E4.0XN ……………………………………………..420
INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS III ……………………422
INTEGRAL SIDE-SHIFT TWO AND THREE STAGE FULL FREE-LIFT – E5.0-5.5XN/E5.0XNS ……………………………424
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS IV ………………………426
INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS IV …………………….428
AUXILIARY TUBE EXTENSIONS TWO STAGE LIMITED FREE LIFT – WITHOUT QUICK DISCONNECT FITTINGS ……………….430
AUXILIARY TUBE EXTENSIONS TWO STAGE LIMITED FREE LIFT – MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ….432
AUXILIARY TUBE EXTENSIONS TWO STAGE LIMITED FREE LIFT – E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ………434
AUXILIARY TUBE EXTENSIONS THREE STAGE FULL FREE-LIFT – WITHOUT QUICK DISCONNECT FITTINGS ……………….438
AUXILIARY TUBE EXTENSIONS THREE STAGE FULL FREE-LIFT – MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ….440
AUXILIARY TUBE EXTENSIONS THREE STAGE FULL FREE-LIFT – E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ………442
AUXILIARY TUBE EXTENSIONS TWO STAGE FULL FREE-LIFT – WITHOUT QUICK DISCONNECT FITTINGS ………………….445
AUXILIARY TUBE EXTENSIONS TWO STAGE FULL FREE- LIFT – MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ……448
AUXILIARY TUBE EXTENSIONS TWO STAGE FULL FREE-LIFT – E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS …………450
FIELD SERVICE KITS…………………………………………………………………………………..453
HYDRAULIC CONVERSION KITS…………………………………………………………………………456
CONVERSION KIT ACCELERATOR PEDAL…………………………………………………………………..456
CONVERSION KIT WIDE TREAD…………………………………………………………………………456
CONVERSION KIT VERTICAL TO SIDE BATTERY REMOVAL OPTION……………………………………………….456
CONVERSION KIT FIXED TO TELESCOPE STEERING COLUMN……………………………………………………456
MISCELLANEOUS CONVERSION KITS……………………………………………………………………..457
ADD ON OPTIONS AUDIBLE ALARM………………………………………………………………………457
ADD ON OPTION KITS LIGHTS…………………………………………………………………………457
ADD ON TELEMETRY KITS…………………………………………………………………………….458
NUMERICAL INDEX……………………………………………………………………………………..459
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