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Hyster Parts Manual For Model h25xm-h30xm-h35xm-h40xm-h40xms
Hyster Parts Manual For Model h25xm-h30xm-h35xm-h40xm-h40xms
MANUAL
CHALLENGER
H25XM, H30XM, H35XM,
H40XM, H40XMS
(D001)
CUSTOMER EDITION
SECTIONS
1 FRAME
2 ENGINE ASSEMBLY
3 FUEL SYSTEM
4 ELECTRICAL SYSTEM
5 TRANSMISSION
6 STEERING SYSTEM
7 BRAKE SYSTEM
8 HYDRAULIC SYSTEM
12 OPTIONS
13 NUMERICAL INDEX
This Parts Manual is divided into 13 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.
UNIT CODE D001
03/2002 NORTH AMERICA
TABLE OF CONTENTS
DESCRIPTION PAGE
A
AIR INTAKE AND FILTER
DIESEL
D/B 11/1996⇒............................................................................................................................................. 3-20
⇒D/B 11/1996............................................................................................................................................. 3-18
GASOLINE AND LPG..................................................................................................................................... 3-16
ALTERNATOR
GASOLINE, LPG, AND DIESEL
STANDARD ................................................................................................................................................. 4-44
TYPE GS, LPS, AND DS ................................................................................................................................ 4-46
AUXILIARY FUNCTION TUBE
TWO AND THREE STAGE FULL FREE-LIFT .............................................................................................. 12-30
TWO STAGE FULL FREE-LIFT .................................................................................................................... 12-28
B
BACKUP ALARM ............................................................................................................................................. 12-26
BATTERY............................................................................................................................................................ 4-14
BRAKE ASSEMBLY
D/B 06/1997⇒ ................................................................................................................................................ 7-14
⇒D/B 06/1997 ................................................................................................................................................ 7-10
BRAKE LINES ...................................................................................................................................................... 7-8
BRAKE LINKAGE
⇒S/N D001H-2628 ........................................................................................................................................... 7-2
S/N D001H-2629⇒ ........................................................................................................................................... 7-4
C
CAMSHAFT AND VALVES
DIESEL ........................................................................................................................................................... 2-32
GASOLINE AND LPG..................................................................................................................................... 2-10
CARBURETOR
GASOLINE...................................................................................................................................................... 3-10
LPG................................................................................................................................................................. 3-12
CARRIAGE
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-26
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-20
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-14
CONTROL VALVE
FOUR FUNCTION
DUAL RELIEF
⇒S/N D001H-3395.................................................................................................................................. 8-54
S/N D001H-3396⇒.................................................................................................................................. 8-58
SINGLE RELIEF
⇒S/N D001H-3395.................................................................................................................................. 8-46
S/N D001H-3396⇒.................................................................................................................................. 8-50
⇒S/N D001H-2628 ......................................................................................................................................... 5-28
S/N D001H-2629⇔S/N D001H-3016 ............................................................................................................. 5-30
S/N D001H-3017⇔S/N PENDING PER ECN 77425 ..................................................................................... 5-32
S/N PENDING PER ECN 77425⇒ ................................................................................................................. 5-34
THREE FUNCTION
DUAL RELIEF
⇒S/N D001H-3395.................................................................................................................................. 8-34
DESCRIPTION PAGE
C (continued)
D
DIFFERENTIAL .................................................................................................................................................. 5-44
DISTRIBUTOR
GASOLINE AND LPG..................................................................................................................................... 4-36
DRIVE AXLE ...................................................................................................................................................... 5-46
DRIVE LIGHTS AND REAR LIGHTS ............................................................................................................... 12-18
DRIVE TIRE AND WHEEL
DISC WHEEL................................................................................................................................................ 12-10
SPLIT WHEELS............................................................................................................................................ 12-12
E
ELECTRICAL
COWL ............................................................................................................................................................. 4-20
ELECTRICAL SYSTEM
DIESEL ............................................................................................................................................................. 4-8
DIESEL ENGINE ............................................................................................................................................ 2-36
ENGINE
DESCRIPTION PAGE
E (continued)
F
FENDER
⇒S/N D001H-3018 ......................................................................................................................................... 12-6
FILTER AND LOCK-OFF VALVE
LPG................................................................................................................................................................. 3-28
FIRE EXTINGUISHER ..................................................................................................................................... 12-22
FLYWHEEL AND TORQUE CONVERTER
⇒S/N D001H-2628 ......................................................................................................................................... 5-36
S/N D001H-2629⇔S/N PENDING PER ECN 76829-10 ................................................................................ 5-38
S/N PENDING PER ECN 76829-10⇒............................................................................................................ 5-40
FORK
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-40
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-34
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-26
FRAME AND FLOOR PLATES............................................................................................................................. 1-2
FREE-LIFT
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-16
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-10
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-24
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-18
FUEL FILTER
DIESEL ........................................................................................................................................................... 3-40
FUEL SUPPLY SYSTEM
LPG................................................................................................................................................................. 3-26
FUEL SYSTEM
DIESEL ........................................................................................................................................................... 3-36
GASOLINE AND LPG..................................................................................................................................... 3-24
DESCRIPTION PAGE
F (continued)
G
GEAR PUMP
⇒S/N D001H-2628 ......................................................................................................................................... 5-42
S/N D001H-2629⇒ ......................................................................................................................................... 5-43
GOVERNOR
GASOLINE AND LPG..................................................................................................................................... 3-14
H
HEADER HOSE
FOUR FUNCTION
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10-36
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-30
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-22
THREE FUNCTION
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10-32
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-26
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-20
HYDRAULIC CLUTCH
⇒S/N D001H-2628 ......................................................................................................................................... 5-16
S/N D001H-2629⇔S/N PENDING PER ECN 86576 ..................................................................................... 5-18
S/N PENDING PER ECN 76829-10⇒............................................................................................................ 5-24
S/N PENDING PER ECN 86576⇔S/N PENDING PER ECN 87177 ............................................................. 5-20
S/N PENDING PER ECN 87177⇔S/N PENDING PER ECN 76829-10 ........................................................ 5-22
HYDRAULIC PUMP
DIESEL
⇒S/N D001H-3304 ..................................................................................................................................... 8-12
GASOLINE AND LPG
⇒S/N D001H-3304 ..................................................................................................................................... 8-10
S/N D001H-3305⇒ ..................................................................................................................................... 8-14
HYDRAULICS
⇒S/N D001H-2081 ........................................................................................................................................... 8-2
S/N D001H-2082⇒ ........................................................................................................................................... 8-6
I
INJECTION PUMP
DIESEL ........................................................................................................................................................... 3-42
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 10-6
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-4
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 9-4
INSTRUMENT CLUSTER .................................................................................................................................. 4-16
INTAKE AND EXHAUST MANIFOLD
DESCRIPTION PAGE
I (continued)
L
LABELS .............................................................................................................................................................. 1-19
LIFT
TWO STAGE LIMITED FREE-LIFT
⇒S/N A550L-1566 ........................................................................................................................................ 9-6
S/N A550L-1567⇒ ........................................................................................................................................ 9-8
LIFT CYLINDER
LEFT HAND
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-10
RIGHT HAND
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-12
LIFTING EYE...................................................................................................................................................... 12-8
LOAD BACKREST EXTENSION
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-28
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-22
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-16
M
MAIN LIFT
THREE STAGE FULL FREE-LIFT
⇒S/N A554L-18550 .................................................................................................................................... 10-8
S/N A554L-1856⇒ .................................................................................................................................... 10-12
TWO STAGE FULL FREE-LIFT
⇒S/N A558L-1559 ...................................................................................................................................... 11-6
S/N A558L-1560⇒ ...................................................................................................................................... 11-8
MAIN LIFT CYLINDER
LEFT HAND
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10-20
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-14
RIGHT HAND
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10-22
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-16
MANIFOLD
INTAKE AND EXHAUST
GASOLINE AND LPG ................................................................................................................................. 2-12
MAST INSTALLATION
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-30
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-24
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-18
MASTER CYLINDER ......................................................................................................................................... 7-20
MIRROR ........................................................................................................................................................... 12-24
MONOTROL PEDAL ............................................................................................................................................ 3-4
DESCRIPTION PAGE
N
NOISE REDUCTION
ENGINE COVER ............................................................................................................................................ 1-24
FRAME ........................................................................................................................................................... 1-22
NON-SUSPENSION SEAT................................................................................................................................. 1-12
NOZZLE HOLDER
DIESEL ........................................................................................................................................................... 3-38
O
OIL PAN AND TIMING GEAR COVER
DIESEL ........................................................................................................................................................... 2-28
GASOLINE AND LPG....................................................................................................................................... 2-6
OIL PUMP AND FILTER
DIESEL ........................................................................................................................................................... 2-38
GASOLINE AND LPG..................................................................................................................................... 2-16
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 10-2
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-2
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 9-2
OVERHEAD GUARD............................................................................................................................................ 1-6
P
PARK BRAKE LEVER ........................................................................................................................................ 7-18
PUMP DRIVE
DIESEL ........................................................................................................................................................... 8-17
GASOLINE AND LPG..................................................................................................................................... 8-16
R
RADIATOR AND HOSES
DIESEL ........................................................................................................................................................... 2-42
GASOLINE AND LPG..................................................................................................................................... 2-20
S
SHIFT LEVER .................................................................................................................................................... 4-18
SIDE-SHIFT CARRIAGE.................................................................................................................................... 12-2
SIDE-SHIFT CYLINDER .................................................................................................................................... 12-4
SOLENOID VALVE ............................................................................................................................................. 5-26
STARTER
DIESEL ........................................................................................................................................................... 4-42
GASOLINE AND LPG
S/N PENDING PER ECN 76195⇒ ............................................................................................................. 4-40
⇒S/N PENDING PER ECN 76195 ............................................................................................................. 4-38
STEER TIRE AND WHEEL
DISC WHEEL................................................................................................................................................ 12-14
SPLIT WHEELS............................................................................................................................................ 12-16
STEERING AXLE ................................................................................................................................................. 6-6
STEERING COLUMN........................................................................................................................................... 6-2
STEERING CONTROL VALVE............................................................................................................................. 6-4
STEERING CYLINDER
S/N PENDING PER ECN 87046-01⇒............................................................................................................ 6-10
⇒S/N PENDING PER ECN 87046-01.............................................................................................................. 6-8
DESCRIPTION PAGE
S (continued)
T
TAIL LIGHTS
EARLY PRODUCTION.................................................................................................................................... 4-12
LATE PRODUCTION ...................................................................................................................................... 4-13
TANK MOUNTING
LPG................................................................................................................................................................. 3-22
THROTTLE........................................................................................................................................................... 3-2
THROTTLE LINKAGE
DIESEL ............................................................................................................................................................. 3-8
GASOLINE........................................................................................................................................................ 3-6
LPG................................................................................................................................................................... 3-7
TILT CYLINDER ................................................................................................................................................. 8-62
TRANSMISSION GEARS
S/N D001H-2629⇒ ......................................................................................................................................... 5-12
S/N D001H-2629⇔S/N PENDING PER ECN 76829-10 ................................................................................ 5-10
S/N PENDING PER ECN 76829-10⇒............................................................................................................ 5-14
TRANSMISSION HOUSING
⇒S/N D001H-2628 ........................................................................................................................................... 5-2
S/N D001H-2629⇔S/N PENDING PER ECN 76829-10 .................................................................................. 5-4
S/N PENDING PER ECN 76829-10⇒.............................................................................................................. 5-6
TRANSMISSION HYDRAULIC LINES
⇒S/N D001H-2628 ......................................................................................................................................... 5-48
S/N D001H-2629⇔S/N D001H-3016 ............................................................................................................. 5-50
S/N D001H-3017⇒ ......................................................................................................................................... 5-52
W
WIRE HARNESS
CLUSTER PANEL........................................................................................................................................... 4-25
CLUSTER POWER......................................................................................................................................... 4-26
COWL
⇒S/N D001H-2209 ..................................................................................................................................... 4-23
S/N D001H-2210⇒ ..................................................................................................................................... 4-24
ENGINE
DIESEL........................................................................................................................................................ 4-32
GASOLINE AND LPG ................................................................................................................................. 4-30
TYPE DS ..................................................................................................................................................... 4-33
TYPE GS AND LPS .................................................................................................................................... 4-31
FORWARD/REVERSE ................................................................................................................................... 4-27
MONOTROL PEDAL....................................................................................................................................... 4-28
SEAT SWITCH................................................................................................................................................ 4-29
TAIL LIGHT ..................................................................................................................................................... 4-34
Listed below are abbreviations used in parts manuals to denote the following expressions:
1. Determine the function and application of the part 9. Quantities shown are for one assembly. The
required. Turn to the Sections Page. Choose the quantities of the subpart BEARING CAP are
general area of reference most likely to include indicated as two and two. This means two per
the part. CASE assembly.
2. Turn to the section you chose. Use the Section 10. Serial number breaks identify the most current
Table of Contents to determine the assembly which parts information and are shown as follows:
would normally contain the part required. Then ⇒ S/N D001H-2628
locate the part on the assembly breakdown page. Indicates last serial number affected.
S/N D001H-2629 ⇒
WHEN THE PART NUMBER IS NOT KNOWN Indicates the first serial number affected.
AND THE NEXT HIGHER ASSEMBLY IS S/N D001H-1553 ⇔ S/N D001H-3291
KNOWN: Indicates a range of serial numbers affected.
3. Determine the assembly the required part is used ECN numbers for pending serial numbers are
on. Turn to the Table of Contents on Page i. shown to allow for the inclusion of the most current
parts information and are identified as follows:
4. Locate the assembly the required part is used on ⇒ S/N Pending Per ECN 63243
and turn to the page indicated for that assembly. Indicates a pending serial number for last unit
Then locate the part on the assembly breakdown affected.
page. S/N Pending Per ECN 63243 ⇒
Indicates a pending serial number for first unit
WHEN THE PART NUMBER IS KNOWN: affected.
5. Use the Numerical Index on Page 13-1 to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
⇒ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00 ⇒
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (. . . . .) within that month for the item affected.
indicate that the part is either Not Serviced D/B 3/00 ⇔ D/B 4/00
Separately or there is a reference to another figure. Indicates a range of production dates of the
A figure reference is denoted by a pointing hand item affected.
followed by a figure number in the DESCRIPTION
column (☞Figure 10) Contact your local dealer for Hyster lift trucks for
serial number information for items with a ECN or
7. Keys are used to show two or more similar a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERING PARTS:
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Hyster lift trucks.
(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.
(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.
(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.
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.
1 FRAME
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 1
FRAME
DESCRIPTION PAGE
FOOTNOTES:
a With Noise Reduction
b ⇒ S/N D001H-3018
c S/N D001H-3019⇔S/N PENDING PER ECN 76392
d S/N PENDING PER ECN 76392 ⇒
1-5
UNIT CODE D001
NORTH AMERICA 03/2002
OVERHEAD GUARD
FOOTNOTES:
a Raised Height
b Standard Height
c Use With Full Suspension Seat
d ⇒ S/N D001H-3305
e S/N D001H-3306 ⇒
ENGINE COVER
KEY:
A: Non-Suspension Seat
B: Suspension Seat
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a ⇒ S/N D001H-3122
b S/N D001H-3123 ⇒
c ⇒ S/N D001H-3305
d S/N D001H-3306 ⇒
SUSPENSION SEAT
NON-SUSPENSION SEAT
LABELS
COUNTERWEIGHT
FOOTNOTES:
a S/N D001H-2784 ⇒
NOISE REDUCTION
FRAME
KEY:
A: Gasoline and LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
NOISE REDUCTION
ENGINE COVER
KEY:
A: Gasoline and LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
1-26
UNIT CODE D001
03/2002 NORTH AMERICA
2 ENGINE ASSEMBLY
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 2
ENGINE ASSEMBLY
DESCRIPTION PAGE
CYLINDER BLOCK
GASOLINE AND LPG
FOOTNOTES:
a Included in Short Block 1360877
FOOTNOTES:
a Included in Short Block 1360877
FOOTNOTES:
a Included in Short Block 1360877
MANIFOLD
INTAKE AND EXHAUST
GASOLINE AND LPG
FOOTNOTES:
a ⇒ S/N D001H-4636
b S/N D001H-4637 ⇒
ELECTRICAL SYSTEM
ENGINE
GASOLINE AND LPG
1 1361868 Screw........................................................................................................................... 1
2 1361878 Screw........................................................................................................................... 2
3 333642 Filter............................................................................................................................. 2
4 1361807 Gasket ......................................................................................................................... 1
5 1361806 Strainer ........................................................................................................................ 1
6 1361801 O-Ring ......................................................................................................................... 1
7 1455675 Oil Pump ...................................................................................................................... 1
8 1368790 Plug ......................................................................................................................... 1
9 1361879 Snap Ring................................................................................................................ 1
10 1361798 Pin ........................................................................................................................... 2
11 1361688 Oil Seal.................................................................................................................... 3
12 1455674 Plunger .................................................................................................................... 1
13 326748 Spring ...................................................................................................................... 1
14 326749 Seat ......................................................................................................................... 1
15 1361802 Cover ....................................................................................................................... 1
16 1455677 Screw ...................................................................................................................... 7
17 1361804 Gear (Inner)............................................................................................................. 1
18 1361805 Gear (Outer) ............................................................................................................ 1
19 1369913 Plate ............................................................................................................................ 1
20 1369914 Bolt .............................................................................................................................. 2
21 1361887 Screw........................................................................................................................... 4
COOLING
GASOLINE AND LPG
FOOTNOTES:
a ⇒ S/N D001H-4636
b S/N D001H-4637 ⇒
FOOTNOTES:
a ⇒ S/N D001H-4749
b S/N D001H-4750 ⇒
CYLINDER HEAD
DIESEL
CYLINDER BLOCK
DIESEL
2-35
UNIT CODE D001
NORTH AMERICA 03/2002
ELECTRICAL SYSTEM
DIESEL ENGINE
COOLING
DIESEL
FOOTNOTES:
a ⇒ S/N D001H-4749
b S/N D001H-4750 ⇒
ENGINE MOUNT
DIESEL
EXHAUST
STANDARD
GASOLINE AND LPG
1 2021354 Muffler.......................................................................................................................... 1
2 a 2021363 Pipe ............................................................................................................................. 1
2 b 2028205 Pipe ............................................................................................................................. 1
3 2037403 Nut ............................................................................................................................... 4
4 320157 Washer ........................................................................................................................ 6
5 2021373 Cover ........................................................................................................................... 1
6 239503 Nut ............................................................................................................................... 2
7 292681 Lockwasher.................................................................................................................. 2
8 2021374 Pipe ............................................................................................................................. 1
9 63117 Clamp .......................................................................................................................... 1
10 1338308 Gasket ......................................................................................................................... 1
11 1351177 Cushion ....................................................................................................................... 4
12 1351176 Washer ........................................................................................................................ 2
13 292517 Capscrew..................................................................................................................... 2
14 2021359 Nut ............................................................................................................................... 2
15 15177 Washer ........................................................................................................................ 2
16 2021370 Clamp .......................................................................................................................... 1
FOOTNOTES:
a ⇒ D/B 12/1997
b D/B 12/1997 ⇒
EXHAUST
STANDARD
DIESEL
1 2021354 Muffler.......................................................................................................................... 1
2 a 2021366 Pipe ............................................................................................................................. 1
2 b 2028206 Pipe ............................................................................................................................. 1
3 320159 Washer ........................................................................................................................ 4
4 2021836 Nut ............................................................................................................................... 4
5 2021377 Pipe ............................................................................................................................. 1
6 63117 Clamp .......................................................................................................................... 1
7 2022496 Gasket ......................................................................................................................... 1
8 1351177 Cushion ....................................................................................................................... 4
9 1351176 Washer ........................................................................................................................ 2
10 292517 Capscrew..................................................................................................................... 2
11 2021359 Nut ............................................................................................................................... 2
12 15177 Washer ........................................................................................................................ 2
13 2021370 Clamp .......................................................................................................................... 1
FOOTNOTES:
a ⇒ D/B 12/1997
b D/B 12/1997 ⇒
EXHAUST
TYPE GS AND LPS
1 2021355 Muffler.......................................................................................................................... 1
2 b 2028205 Pipe ............................................................................................................................. 1
2 a 2021363 Pipe ............................................................................................................................. 1
3 2037403 Nut ............................................................................................................................... 4
4 320157 Washer ........................................................................................................................ 6
5 2021373 Cover ........................................................................................................................... 1
6 239503 Nut ............................................................................................................................... 2
7 292681 Lockwasher.................................................................................................................. 2
8 1338308 Gasket ......................................................................................................................... 1
9 1351177 Cushion ....................................................................................................................... 4
10 1351176 Washer ........................................................................................................................ 2
11 292517 Capscrew..................................................................................................................... 2
12 2021359 Nut ............................................................................................................................... 2
13 15177 Washer ........................................................................................................................ 2
14 2021370 Clamp .......................................................................................................................... 1
FOOTNOTES:
a ⇒ D/B 12/1997
b D/B 12/1997 ⇒
EXHAUST
TYPE DS
1 2021355 Muffler.......................................................................................................................... 1
2 a 2021366 Pipe ............................................................................................................................. 1
2 b 2028206 Pipe ............................................................................................................................. 1
3 320159 Washer ........................................................................................................................ 4
4 2021836 Nut ............................................................................................................................... 4
5 2022496 Gasket ......................................................................................................................... 1
6 1351177 Cushion ....................................................................................................................... 4
7 1351176 Washer ........................................................................................................................ 2
8 292517 Capscrew..................................................................................................................... 2
9 2021359 Nut ............................................................................................................................... 2
10 15177 Washer ........................................................................................................................ 2
11 2021370 Clamp .......................................................................................................................... 1
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 87460
b S/N PENDING PER ECN 87460 ⇒
EXHAUST
OVERHEAD
GASOLINE AND LPG
1 2021354 Muffler.......................................................................................................................... 1
2 b 2028205 Pipe ............................................................................................................................. 1
2 a 2021363 Pipe ............................................................................................................................. 1
3 2037403 Nut ............................................................................................................................... 4
4 320157 Washer ........................................................................................................................ 5
5 2021373 Cover ........................................................................................................................... 1
6 239503 Nut ............................................................................................................................... 2
7 292681 Lockwasher.................................................................................................................. 2
8 2021379 Pipe ............................................................................................................................. 1
9 63117 Clamp .......................................................................................................................... 1
10 2026853 Tail Pipe ....................................................................................................................... 1
11 136985 Capscrew..................................................................................................................... 3
12 292682 Lockwasher.................................................................................................................. 3
13 15176 Washer ........................................................................................................................ 1
14 320159 Washer ........................................................................................................................ 1
15 2021394 Cover ........................................................................................................................... 1
16 1351177 Cushion ....................................................................................................................... 4
17 1351176 Washer ........................................................................................................................ 2
18 292517 Capscrew..................................................................................................................... 2
19 2021359 Nut ............................................................................................................................... 2
20 15177 Washer ........................................................................................................................ 2
21 2021370 Clamp .......................................................................................................................... 1
22 1338308 Gasket ......................................................................................................................... 1
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 87460
b S/N PENDING PER ECN 87460 ⇒
EXHAUST
OVERHEAD
DIESEL
1 2021354 Muffler.......................................................................................................................... 1
2 a 2021366 Pipe ............................................................................................................................. 1
2 b 2028206 Pipe ............................................................................................................................. 1
3 320159 Washer ........................................................................................................................ 1
4 2021836 Nut ............................................................................................................................... 4
5 2021382 Pipe ............................................................................................................................. 1
6 63117 Clamp .......................................................................................................................... 1
7 2026015 Pipe ............................................................................................................................. 1
8 136985 Capscrew..................................................................................................................... 3
9 292682 Lockwasher.................................................................................................................. 3
10 15176 Washer ........................................................................................................................ 1
11 2021394 Cover ........................................................................................................................... 1
12 1351177 Cushion ....................................................................................................................... 4
13 1351176 Washer ........................................................................................................................ 2
14 292517 Capscrew..................................................................................................................... 3
15 2021359 Nut ............................................................................................................................... 2
16 15177 Washer ........................................................................................................................ 2
17 2021370 Clamp .......................................................................................................................... 1
18 2022496 Gasket ......................................................................................................................... 1
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 87460
b S/N PENDING PER ECN 87460 ⇒
2-58
UNIT CODE D001
03/2002 NORTH AMERICA
3 FUEL SYSTEM
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 3
FUEL SYSTEM
DESCRIPTION PAGE
THROTTLE
KEY:
A: Monotrol Pedal
B: Forward/Reverse Lever
QTY
ITEM PART NO. DESCRIPTION A B
1 353397 Pedal (☞ Figure 3-2) .......................................................................................... 1 ..
2 352499 Pedal.................................................................................................................... .. 1
3 352885 Pad ...................................................................................................................... .. 1
4 292521 Capscrew............................................................................................................. .. 1
4 292523 Capscrew............................................................................................................. 1 ..
5 320160 Washer ................................................................................................................ 2 2
6 325708 Tube ..................................................................................................................... .. 1
6 353141 Tube ..................................................................................................................... 1 ..
7 353143 Spring .................................................................................................................. 1 1
8 353142 Spring .................................................................................................................. 1 1
9 136985 Capscrew............................................................................................................. 1 2
10 292682 Lockwasher.......................................................................................................... 4 4
11 353195 Bumper ................................................................................................................ 1 1
12 352950 Bracket................................................................................................................. 1 ..
12 353159 Bracket................................................................................................................. .. 1
13 15212 Cotter Pin............................................................................................................. 1 ..
14 239503 Nut ....................................................................................................................... 1 ..
15 292681 Lockwasher.......................................................................................................... 2 ..
16 353453 Mount................................................................................................................... 1 ..
17 353172 Spring .................................................................................................................. 1 ..
18 353230 Cap ...................................................................................................................... 1 ..
19 142 Pin ....................................................................................................................... 1 ..
20 320158 Washer ................................................................................................................ 1 ..
21 287851 Capscrew............................................................................................................. 1 ..
22 136692 Nut ....................................................................................................................... 2 2
23 296128 Nut ....................................................................................................................... .. 1
24 352485 Shaft .................................................................................................................... 1 1
25 15200 Cotter Pin............................................................................................................. 1 1
26 320156 Washer ................................................................................................................ 1 1
27 353164 Crank ................................................................................................................... 1 1
28 353129 Rod ...................................................................................................................... 1 1
29 2021421 Bracket................................................................................................................. 1 1
30 2021426 Bracket................................................................................................................. 1 1
31 296166 Capscrew............................................................................................................. 2 2
32 292514 Capscrew............................................................................................................. 2 2
MONOTROL PEDAL
353397 Pedal............................................................................................................................ ..
1 .. . . . Pedal ....................................................................................................................... 1
2 135685 Bushing ................................................................................................................... 2
3 353175 Pad .......................................................................................................................... 1
3 .. . . . Pad...................................................................................................................... 1
4 .. . . . Plate.................................................................................................................... 1
4 352990 Adhesive ............................................................................................................. AR
5 186493 Screw .................................................................................................................. 1
6 15152 Lockwasher ......................................................................................................... 1
7 359207 Plate ........................................................................................................................ 2
8 57568 O-Ring ..................................................................................................................... 8
9 352969 Screw ...................................................................................................................... 6
10 353448 Washer .................................................................................................................... 4
11 353154 Pin ........................................................................................................................... 1
12 220932 Screw ...................................................................................................................... 2
12 360387 Sealant .................................................................................................................... AR
13 353165 Retainer................................................................................................................... 1
14 353441 Magnet and Nut Assembly ...................................................................................... 2
14 353422 Magnet ................................................................................................................ 1
15 353432 Nut ...................................................................................................................... 1
16 220434 Capscrew ................................................................................................................ 2
17 53162 Lockwasher ............................................................................................................. 2
18 16865 Nut........................................................................................................................... 2
19 114312 Strap Clamp ............................................................................................................ 3
20 1352090 Switch Assembly ..................................................................................................... 1
20 353128 Switch ................................................................................................................. 2
21 .. . . . Jumper Wire........................................................................................................ 1
22 .. . . . Jumper Wire........................................................................................................ 1
23 .. . . . Wire Harness ...................................................................................................... 1
24 353168 Spring ...................................................................................................................... 1
3-9
UNIT CODE D001
NORTH AMERICA 03/2002
CARBURETOR
GASOLINE
2022908 Carburetor.................................................................................................................... 1
1 1369815 Bolt .......................................................................................................................... 2
2 1369816 Holder...................................................................................................................... 1
3 326742 Clamp ...................................................................................................................... 1
4 1369817 Air Horn ................................................................................................................... 1
5 1369818 Rod.......................................................................................................................... 1
6 1369819 Hanger..................................................................................................................... 1
7 1369820 Spring ...................................................................................................................... 1
8 326721 Solenoid .................................................................................................................. 1
9 326716 Screw ...................................................................................................................... 1
10 1369822 Lever Set ................................................................................................................. 1
11 1369823 Throttle Body Assembly .......................................................................................... 1
12 1369824 Strainer Set ............................................................................................................. 1
13 326741 Connector................................................................................................................ 1
14 326733 Valve Seat (Float) .................................................................................................... 1
15 326744 Screw (With Washer)............................................................................................... 5
16 326719 Lever........................................................................................................................ 1
17 326720 Screw ...................................................................................................................... 1
18 326718 Jet............................................................................................................................ 1
19 1369825 Jet............................................................................................................................ 1
20 326726 Jet and Seat Assembly............................................................................................ 1
21 326730 Accelerator Pump Assembly ................................................................................... 1
22 1369826 Valve (Power) .......................................................................................................... 1
23 326732 Weight Set............................................................................................................... 1
24 326731 Float ........................................................................................................................ 1
25 326729 Plug ......................................................................................................................... 1
26 1369827 Jet (Main) ................................................................................................................ 1
27 1369828 Screw ...................................................................................................................... 1
28 1369829 Idle Adjust Kit .......................................................................................................... 1
29 326739 Clip .......................................................................................................................... 1
30 326725 Jet Assembly ........................................................................................................... 1
31 326743 Gasket Kit................................................................................................................ 1
CARBURETOR
LPG
3-15
UNIT CODE D001
NORTH AMERICA 03/2002
TANK MOUNTING
LPG
1 2022568 Bracket......................................................................................................................... 1
2 287854 Capscrew..................................................................................................................... 5
3 292682 Lockwasher.................................................................................................................. 5
4 320159 Washer ........................................................................................................................ 2
5 316826 Nut ............................................................................................................................... 4
6 292683 Lockwasher.................................................................................................................. 1
7 296130 Nut ............................................................................................................................... 1
8 1339769 Strap ............................................................................................................................ 1
9 136692 Nut ............................................................................................................................... 2
10 196297 Latch ............................................................................................................................ 1
11 147294 Nut ............................................................................................................................... 1
12 2022853 Bracket......................................................................................................................... 1
13 2022566 Pin ............................................................................................................................... 1
14 97999 Disconnect................................................................................................................... 1
15 1327554 Fitting........................................................................................................................... 1
16 1328879 Hose ............................................................................................................................ 1
17 16863 Fitting........................................................................................................................... 1
18 101809 Valve ............................................................................................................................ 1
19 2021712 Hose ............................................................................................................................ 1
20 2021720 Adapter ........................................................................................................................ 1
21 320173 Washer ........................................................................................................................ 2
22 296138 Nut ............................................................................................................................... 1
23 1328890 Tank ............................................................................................................................. 1
24 344229 Gauge (Screw On 1-1/4 NPT) ................................................................................. 1
24 1332400 Gauge (Screw On 3/4 NPT) .................................................................................... 1
24 197040 Gauge (Bolt On Type).............................................................................................. 1
25 200170 Relief Valve ............................................................................................................. 1
26 344228 Adapter.................................................................................................................... 1
27 200172 Cap.......................................................................................................................... 1
28 233908 Valve........................................................................................................................ 1
29 124010 Coupling .................................................................................................................. 1
30 1337614 Valve (Optional) ........................................................................................................... 1
30 15963 Fitting........................................................................................................................... 1
FUEL SYSTEM
GASOLINE AND LPG
KEY:
A: Gasoline
B: LPG
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a ⇒ S/N D001H-4636
b S/N D001H-4637 ⇒
2026725 Repair Kit (Includes Items 1, 3-4, 8-10, 13, 15, 17, 19) ............................................... 1
CONVERTER
LPG
IDENTIFY BY VENDOR MODEL CODE "J"
204837 Converter Repair Kit (Includes Items 1, 4-5, 8, 13-14, 18-19, 21) ............................... 1
CONVERTER
LPG
IDENTIFY BY VENDOR MODEL CODE "K"
(⇒S/N D001H-4636)
2023646 Converter Repair Kit (Includes Items 1, 3-5, 9, 13, 17-18) .......................................... 1
2026721 Repair Kit (Includes Items 1, 3-5, 9, 13, 17-18) ........................................................... 1
FOOTNOTES:
a Not Illustrated
b ⇒ S/N D001B-4416
c S/N D001B-4417 ⇒
FOOTNOTES:
a Not Illustrated
3-35
UNIT CODE D001
NORTH AMERICA 03/2002
FUEL SYSTEM
DIESEL
NOZZLE HOLDER
DIESEL
FUEL FILTER
DIESEL
INJECTION PUMP
DIESEL
1366852 Repair Kit (Includes Items 7, 9, 12-13, 15, 21, 24, 26, 28, 32) .................................... 1
3-48
UNIT CODE D001
03/2002 NORTH AMERICA
4 ELECTRICAL SYSTEM
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 4
ELECTRICAL SYSTEM
DESCRIPTION PAGE
ALTERNATOR
GASOLINE, LPG, AND DIESEL
STANDARD ................................................................................................................................................. 4-44
TYPE GS, LPS, AND DS ................................................................................................................................ 4-46
BATTERY............................................................................................................................................................ 4-14
DISTRIBUTOR
GASOLINE AND LPG..................................................................................................................................... 4-36
ELECTRICAL
COWL ............................................................................................................................................................. 4-20
ELECTRICAL SYSTEM
DIESEL ............................................................................................................................................................. 4-8
GASOLINE AND LPG....................................................................................................................................... 4-2
TYPE DS......................................................................................................................................................... 4-10
TYPE GS AND LPS .......................................................................................................................................... 4-6
INSTRUMENT CLUSTER .................................................................................................................................. 4-16
SHIFT LEVER .................................................................................................................................................... 4-18
STARTER
DIESEL ........................................................................................................................................................... 4-42
GASOLINE AND LPG
S/N PENDING PER ECN 76195⇒ ............................................................................................................. 4-40
⇒S/N PENDING PER ECN 76195 ............................................................................................................. 4-38
TAIL LIGHTS
EARLY PRODUCTION.................................................................................................................................... 4-12
LATE PRODUCTION ...................................................................................................................................... 4-13
WIRE HARNESS
CLUSTER PANEL........................................................................................................................................... 4-25
CLUSTER POWER......................................................................................................................................... 4-26
COWL
⇒S/N D001H-2209 ..................................................................................................................................... 4-23
S/N D001H-2210⇒ ..................................................................................................................................... 4-24
ENGINE
DIESEL........................................................................................................................................................ 4-32
GASOLINE AND LPG ................................................................................................................................. 4-30
TYPE DS ..................................................................................................................................................... 4-33
TYPE GS AND LPS .................................................................................................................................... 4-31
FORWARD/REVERSE ................................................................................................................................... 4-27
MONOTROL PEDAL....................................................................................................................................... 4-28
SEAT SWITCH................................................................................................................................................ 4-29
TAIL LIGHT ..................................................................................................................................................... 4-34
ELECTRICAL SYSTEM
GASOLINE AND LPG
KEY:
A: Gasoline
B: LPG
QTY
ITEM PART NO. DESCRIPTION A B
1 292500 Capscrew............................................................................................................. 2 2
2 136687 Nut ....................................................................................................................... 2 2
3 292680 Lockwasher.......................................................................................................... 2 2
4 320156 Washer ................................................................................................................ 2 2
5 292668 Nut ....................................................................................................................... 1 1
6 292679 Lockwasher.......................................................................................................... 1 1
7 239503 Nut ....................................................................................................................... 1 1
8 292681 Lockwasher.......................................................................................................... 1 1
9 2026608 Pressure Switch................................................................................................... 1 1
10 292680 Lockwasher.......................................................................................................... 1 1
11 2022614 Nut ....................................................................................................................... 1 1
12 1367633 Temperature Sender ............................................................................................ 1 1
13 2021986 Battery Cable....................................................................................................... 1 1
14 2021996 Wire Harness....................................................................................................... 1 1
15 302285 Capscrew............................................................................................................. 1 1
16 292682 Lockwasher.......................................................................................................... 1 1
17 2022013 Clamp .................................................................................................................. 5 5
18 136681 Capscrew............................................................................................................. 1 1
19 239503 Nut ....................................................................................................................... 1 1
20 292681 Lockwasher.......................................................................................................... 3 3
21 137852 Strap Clamp......................................................................................................... AR AR
22 257241 Cover ................................................................................................................... 1 1
23 316678 Screw................................................................................................................... 2 2
24 2021985 Battery Cable....................................................................................................... 1 1
25 2021994 Wire Harness (Gas and LPG) (☞ Figure 4-17) .................................................. 1 1
25 2021995 Wire Harness (Diesel) (☞ Figure 4-17) ............................................................. 1 1
26 2022502 Boot ..................................................................................................................... 1 1
27 2021987 Battery Cable....................................................................................................... 1 1
28 e 2021998 Wire Harness (☞ Figure 4-18) ........................................................................... 1 1
28 f 2026640 Wire Harness (☞ Figure 4-18) ........................................................................... 1 1
29 a 2030223 Wire Harness (☞ Figure 4-16) ........................................................................... 1 1
30 a 2021434 Switch .................................................................................................................. 1 1
31 2022003 Wire Harness....................................................................................................... .. 1
32 190383 Boot ..................................................................................................................... .. 1
33 329067 Screw................................................................................................................... .. 1
34 292681 Lockwasher.......................................................................................................... .. 1
35 2021440 Ignition Coil .......................................................................................................... 1 1
36 bc 2022004 Wire Harness....................................................................................................... 1 1
36 bd 2314343 Wire Harness....................................................................................................... 1 1
37 bc 2022517 Sensor ................................................................................................................. 1 1
37 bd 2314346 Sensor ................................................................................................................. 1 1
38 b 2022521 Wire Harness....................................................................................................... 1 1
39 b 1356108 Pressure Sender.................................................................................................. 1 1
40 b 16186 Fitting................................................................................................................... 1 1
41 b 367224 Fitting................................................................................................................... 1 1
42 b 324740 Connector ............................................................................................................ 1 1
ELECTRICAL SYSTEM
GASOLINE AND LPG
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Monotrol Pedal
b Premium
c ⇒ S/N PENDING PER ECN 76215
d S/N PENDING PER ECN 76215 ⇒
e ⇒ S/N PENDING PER ECN 86982
f S/N PENDING PER ECN 86982 ⇒
4-5
UNIT CODE D001
NORTH AMERICA 03/2002
ELECTRICAL SYSTEM
TYPE GS AND LPS
1 2021966 Bracket......................................................................................................................... 1
2 2021968 Strap ............................................................................................................................ 1
3 2021963 Alternator (☞ Figure 4-28) ......................................................................................... 1
3 2022525 Alternator (☞ Figure 4-28) ......................................................................................... 1
4 320159 Washer ........................................................................................................................ 3
5 292682 Lockwasher.................................................................................................................. 3
6 2022524 Bolt .............................................................................................................................. 3
7 18497 Capscrew..................................................................................................................... 1
8 292681 Lockwasher.................................................................................................................. 1
9 320157 Washer ........................................................................................................................ 1
10 292532 Capscrew..................................................................................................................... 1
11 320161 Washer ........................................................................................................................ 1
12 2021237 Nut ............................................................................................................................... 1
13 2022502 Boot ............................................................................................................................. 1
14 2021988 Battery Cable............................................................................................................... 1
15 2021989 Battery Cable............................................................................................................... 1
16 a 2021999 Wire Harness (☞ Figure 4-19) ................................................................................... 1
16 b 2026641 Wire Harness (☞ Figure 4-19) ................................................................................... 1
17 2022008 Plate ............................................................................................................................ 1
18 2022009 Strap ............................................................................................................................ 1
19 136681 Capscrew..................................................................................................................... 1
20 239503 Nut ............................................................................................................................... 1
21 320157 Washer ........................................................................................................................ 1
22 2022010 Protective Sleeve ......................................................................................................... 1
23 2022503 Cap .............................................................................................................................. 1
24 2022011 Protective Sleeve ......................................................................................................... 1
25 1324517 Disconnect Switch ....................................................................................................... 1
26 2022608 Plate ............................................................................................................................ 1
27 222021 Rivet............................................................................................................................. 4
28 2021166 Starter (☞ Figure 4-26) .............................................................................................. 1
28 2022609 Starter (Type DS) (☞ Figure 4-26) ............................................................................. 1
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 86982
b S/N PENDING PER ECN 86982 ⇒
ELECTRICAL SYSTEM
DIESEL
FOOTNOTES:
a Monotrol Pedal
b Premium
c ⇒ S/N PENDING PER ECN 87791
d S/N PENDING PER ECN 87791 ⇒
ELECTRICAL SYSTEM
TYPE DS
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 77798
b S/N PENDING PER ECN 77798 ⇒
KEY:
A: Gasoline and LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
1 2314251 Battery ................................................................................................................. 1 ..
2 2314252 Battery ................................................................................................................. .. 1
3 2021943 Clamp .................................................................................................................. 1 ..
4 1332658 Battery Hold Down............................................................................................... .. 1
5 2030198 Rod ...................................................................................................................... 2 2
6 1326939 Cap ...................................................................................................................... 2 2
7 136687 Nut ....................................................................................................................... 2 2
8 292680 Lockwasher.......................................................................................................... 2 2
9 320156 Washer ................................................................................................................ 2 2
10 2021947 Battery Tray.......................................................................................................... 1 ..
11 2021948 Battery Tray.......................................................................................................... .. 1
12 316678 Screw................................................................................................................... 3 1
13 292681 Lockwasher.......................................................................................................... 3 3
14 320157 Washer ................................................................................................................ 3 3
15 136749 Capscrew............................................................................................................. .. 2
16 239503 Nut ....................................................................................................................... .. 2
4-15
UNIT CODE D001
NORTH AMERICA 03/2002
INSTRUMENT CLUSTER
KEY:
A: Premium Gauges
B: Standard Gauges
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Diesel
b Gasoline
c LPG
SHIFT LEVER
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 73615
b S/N PENDING PER ECN 73615 ⇒
ELECTRICAL
COWL
KEY:
A: Types G, LP, and D
B: Types GS, LPS, and DS
QTY
ITEM PART NO. DESCRIPTION A B
ELECTRICAL
COWL
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Forward/Reverse Lever
b Monotrol Pedal
c ⇒ S/N D001H-1751
d S/N D001H-1752 ⇒
e ⇒ S/N PENDING PER ECN 76392
f S/N PENDING PER ECN 76392 ⇒
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 76392
b S/N PENDING PER ECN 76392 ⇒
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 86982
b S/N PENDING PER ECN 86982 ⇒
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 86982
b S/N PENDING PER ECN 86982 ⇒
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 87791
b S/N PENDING PER ECN 87791 ⇒
4-35
UNIT CODE D001
NORTH AMERICA 03/2002
DISTRIBUTOR
GASOLINE AND LPG
FOOTNOTES:
a ⇒ D/B 12/1997
b D/B 12/1997 ⇒
STARTER
GASOLINE AND LPG
(⇒S/N PENDING PER ECN 76195)
a 1362069 Starter.......................................................................................................................... 1
1 1368862 Switch...................................................................................................................... 1
2 1368849 Bracket .................................................................................................................... 1
3 1368858 Sleeve ................................................................................................................. 1
4 1368860 Brush Holder ........................................................................................................... 1
5 326889 Brush Spring ....................................................................................................... 3
6 1368861 Brush................................................................................................................... 1
7 1368857 Bracket .................................................................................................................... 1
8 1368859 Sleeve ................................................................................................................. 1
9 1368848 Yoke......................................................................................................................... 1
10 1368863 Brush................................................................................................................... 2
11 1368850 Stopper.................................................................................................................... 1
12 1368851 Armature...................................................................................................................... 1
13 1368852 Clutch ...................................................................................................................... 1
14 1368853 Screw ...................................................................................................................... 1
15 1368854 Washer .................................................................................................................... 1
16 1368855 Lever........................................................................................................................ 1
17 1368856 Bolt .......................................................................................................................... 2
FOOTNOTES:
a Service with Part No. 2034921
STARTER
GASOLINE AND LPG
(S/N PENDING PER ECN 76195⇒)
2314322 Starter.......................................................................................................................... 1
1 2314323 Armature ................................................................................................................. 1
2 2314324 Shaft ........................................................................................................................ 1
3 2314325 Shaft.................................................................................................................... 1
4 2314326 Gear .................................................................................................................... 1
5 2314327 Gear .................................................................................................................... 3
6 2314328 Pinion Set............................................................................................................ 1
7 2314328 Pinion Set............................................................................................................ 1
8 2314330 Packing.................................................................................................................... 1
9 2314331 Ball .......................................................................................................................... 1
10 2314332 Yoke......................................................................................................................... 1
11 2314333 Brush ....................................................................................................................... 1
12 2314335 Spring.................................................................................................................. 1
12 2314336 Spring.................................................................................................................. 1
12 2314334 Brush Holder ........................................................................................................... 1
13 2314337 Bracket .................................................................................................................... 1
14 2314338 Bearing................................................................................................................ 1
15 2314339 Bearing .................................................................................................................... 1
16 1368858 Sleeve ................................................................................................................. 1
17 2314340 Bolt .......................................................................................................................... 2
18 2314341 Lever........................................................................................................................ 1
19 2314342 Switch...................................................................................................................... 1
20 1368853 Screw ...................................................................................................................... 1
STARTER
DIESEL
ALTERNATOR
GASOLINE, LPG, AND DIESEL
STANDARD
KEY:
A: Canister Condensor
B: Resin Condensor
QTY
ITEM PART NO. DESCRIPTION A B
ALTERNATOR
TYPE GS, LPS, AND DS
4-48
UNIT CODE D001
03/2002 NORTH AMERICA
5 TRANSMISSION
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 5
TRANSMISSION
DESCRIPTION PAGE
CONTROL VALVE
⇒S/N D001H-2628 ......................................................................................................................................... 5-28
S/N D001H-2629⇔S/N D001H-3016 ............................................................................................................. 5-30
S/N D001H-3017⇔S/N PENDING PER ECN 77425 ..................................................................................... 5-32
S/N PENDING PER ECN 77425⇒ ................................................................................................................. 5-34
DIFFERENTIAL .................................................................................................................................................. 5-44
DRIVE AXLE ...................................................................................................................................................... 5-46
END PLATE ........................................................................................................................................................ 5-54
FLYWHEEL AND TORQUE CONVERTER
⇒S/N D001H-2628 ......................................................................................................................................... 5-36
S/N D001H-2629⇔S/N PENDING PER ECN 76829-10 ................................................................................ 5-38
S/N PENDING PER ECN 76829-10⇒............................................................................................................ 5-40
GEAR PUMP
⇒S/N D001H-2628 ......................................................................................................................................... 5-42
S/N D001H-2629⇒ ......................................................................................................................................... 5-43
HYDRAULIC CLUTCH
⇒S/N D001H-2628 ......................................................................................................................................... 5-16
S/N D001H-2629⇔S/N PENDING PER ECN 86576 ..................................................................................... 5-18
S/N PENDING PER ECN 76829-10⇒............................................................................................................ 5-24
S/N PENDING PER ECN 86576⇔S/N PENDING PER ECN 87177 ............................................................. 5-20
S/N PENDING PER ECN 87177⇔S/N PENDING PER ECN 76829-10 ........................................................ 5-22
SOLENOID VALVE ............................................................................................................................................. 5-26
TRANSMISSION GEARS
S/N D001H-2629⇒ ......................................................................................................................................... 5-12
S/N D001H-2629⇔S/N PENDING PER ECN 76829-10 ................................................................................ 5-10
S/N PENDING PER ECN 76829-10⇒............................................................................................................ 5-14
TRANSMISSION HOUSING
⇒S/N D001H-2628 ........................................................................................................................................... 5-2
S/N D001H-2629⇔S/N PENDING PER ECN 76829-10 .................................................................................. 5-4
S/N PENDING PER ECN 76829-10⇒.............................................................................................................. 5-6
TRANSMISSION HYDRAULIC LINES
⇒S/N D001H-2628 ......................................................................................................................................... 5-48
S/N D001H-2629⇔S/N D001H-3016 ............................................................................................................. 5-50
S/N D001H-3017⇒ ......................................................................................................................................... 5-52
TRANSMISSION HOUSING
(⇒S/N D001H-2628)
KEY:
A: Gasoline and LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
2022547 Transmission........................................................................................................ 1 ..
2023329 Transmission........................................................................................................ .. 1
1 2021670 Case Assembly ............................................................................................... 1 1
2 2023418 Bearing Cap ................................................................................................ 2 2
3 296426 Washer........................................................................................................ 4 4
4 293692 Capscrew .................................................................................................... 4 4
5 2021390 Cover ............................................................................................................... 1 1
6 1371656 Cotter Pin ........................................................................................................ 2 2
7 2021329 O-Ring ............................................................................................................. 2 2
8 2021915 Plug ................................................................................................................. 4 4
9 2021675 Housing ........................................................................................................... 1 1
10 2021336 Pin ................................................................................................................... 4 4
11 287860 Capscrew ........................................................................................................ 22 22
12 292682 Lockwasher ..................................................................................................... 39 39
13 2021344 Gear Pump (☞ Figure 5-20) .......................................................................... 1 1
14 2021345 Gasket ............................................................................................................. 1 1
15 214364 Capscrew ........................................................................................................ 8 8
16 296418 Washer ............................................................................................................ 8 8
17 2021388 Temperature Switch......................................................................................... 1 1
18 2021389 Breather........................................................................................................... 1 1
19 2021383 Dipstick............................................................................................................ 1 1
20 292515 Capscrew ........................................................................................................ 9 9
21 136692 Nut................................................................................................................... 9 9
22 292527 Capscrew ........................................................................................................ 2 ..
23 292531 Capscrew ........................................................................................................ .. 3
24 292683 Lockwasher ..................................................................................................... 2 3
25 293637 Capscrew ........................................................................................................ 4 4
26 296420 Washer ............................................................................................................ 4 4
27 2021678 Torque Converter (☞ Figure 5-17) ................................................................. 1 ..
27 2021351 Torque Converter (☞ Figure 5-17) ................................................................. .. 1
28 2021362 Flywheel (☞ Figure 5-17) .............................................................................. 1 ..
28 2021368 Flywheel (☞ Figure 5-17) .............................................................................. .. 1
TRANSMISSION HOUSING
(S/N D001H-2629⇔S/N PENDING PER ECN 76829-10)
KEY:
A: Gasoline and LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
2023970 Transmission........................................................................................................ 1 ..
2023971 Transmission........................................................................................................ .. 1
1 2026113 Case Assembly ............................................................................................... 1 1
2 2023418 Bearing Cap ................................................................................................ 2 2
3 296426 Washer........................................................................................................ 4 4
4 293692 Capscrew .................................................................................................... 4 4
5 2021390 Cover ............................................................................................................... 1 1
6 1371656 Cotter Pin ........................................................................................................ 2 2
7 2021329 O-Ring ............................................................................................................. 2 2
8 2021915 Plug ................................................................................................................. 4 4
9 ac 2023928 Housing ........................................................................................................... 1 1
9 bde 2026112 Housing ........................................................................................................... 1 1
9 f 2026592 Housing ........................................................................................................... 1 1
10 2021336 Pin ................................................................................................................... 4 4
11 2023422 Bolt .................................................................................................................. 10 10
12 292682 Lockwasher ..................................................................................................... 38 38
13 2023917 Gear Pump (☞ Figure 5-21) .......................................................................... 1 1
14 2022354 Pipe ................................................................................................................. 1 1
15 214364 Capscrew ........................................................................................................ 5 5
16 296418 Washer ............................................................................................................ 5 5
17 2021388 Temperature Switch......................................................................................... 1 1
18 2021389 Breather........................................................................................................... 1 1
19 2021383 Dipstick............................................................................................................ 1 1
20 292515 Capscrew ........................................................................................................ 9 9
21 136692 Nut................................................................................................................... 9 9
22 292527 Capscrew ........................................................................................................ 2 ..
22 292531 Capscrew ........................................................................................................ .. 3
23 292683 Lockwasher ..................................................................................................... 2 3
24 292531 Capscrew ........................................................................................................ 4 4
25 2023976 Plug ................................................................................................................. 1 1
26 2021917 Plug ................................................................................................................. 1 1
27 2035509 Torque Converter (☞ Figure 5-18) ................................................................. 1 1
28 2030242 Flywheel (☞ Figure 5-18) .............................................................................. 1 ..
28 2021368 Flywheel (☞ Figure 5-18) .............................................................................. .. 1
FOOTNOTES:
a ⇒ S/N D001B-4526
b S/N D001B-4527 ⇒
c ⇒ S/N D001H-2763
d S/N D001H-2764 ⇒
e ⇒ S/N D001H-3149
f S/N D001H-3150 ⇒
TRANSMISSION HOUSING
(S/N PENDING PER ECN 76829-10⇒)
TRANSMISSION HOUSING
(S/N PENDING PER ECN 76829-10⇒)
FOOTNOTES:
a Not Illustrated
5-9
UNIT CODE D001
NORTH AMERICA 03/2002
TRANSMISSION GEARS
(S/N D001H-2629⇔S/N PENDING PER ECN 76829-10)
KEY:
A: Gasoline and LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
2022547 Transmission........................................................................................................ 1 ..
2023329 Transmission........................................................................................................ .. 1
1 2021293 Shim (0.003 in.) ............................................................................................... AR AR
1 2021294 Shim (0.007 in.) ............................................................................................... AR AR
1 2021295 Shim (0.011 in.) ............................................................................................... AR AR
1 2021296 Shim (0.015 in.) ............................................................................................... AR AR
1 2021298 Shim (0.019 in.) ............................................................................................... AR AR
2 2022352 Roller Bearing ................................................................................................. 2 2
3 2021299 Oil Seal............................................................................................................ 1 1
4 2021300 Bearing ............................................................................................................ 1 1
5 2021301 Gear ................................................................................................................ 1 ..
5 2021302 Gear ................................................................................................................ .. 1
6 2021912 Nut................................................................................................................... 1 1
7 2021303 Nut................................................................................................................... 1 1
8 2021305 Lockwasher ..................................................................................................... 1 1
9 2021914 Washer ............................................................................................................ 1 1
10 2021309 Shaft (Reverse) ............................................................................................... 1 ..
10 2021313 Shaft (Reverse) ............................................................................................... .. 1
11 2021314 Plate ................................................................................................................ 1 1
12 287851 Capscrew ........................................................................................................ 2 2
13 292681 Lockwasher ..................................................................................................... 2 2
14 2021300 Bearing ............................................................................................................ 1 1
15 2021318 Bearing ............................................................................................................ 1 1
16 2021319 Gear (Reverse)................................................................................................ 1 1
17 2021320 Washer ............................................................................................................ 1 1
18 2021321 Snap Ring........................................................................................................ 1 1
19 3041266 Snap Ring........................................................................................................ 2 2
20 2021344 Gear Pump (☞ Figure 5-7) ............................................................................ 1 1
21 1368867 Bolt .................................................................................................................. 2 2
22 292680 Lockwasher ..................................................................................................... 2 2
23 2021283 Gear Service Kit .............................................................................................. 1 1
TRANSMISSION GEARS
(S/N D001H-2629⇒)
KEY:
A: Gasoline and LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
2023970 Transmission........................................................................................................ 1 ..
2023971 Transmission........................................................................................................ .. 1
1 2021293 Shim (0.003 in.) (0.10 mm) ............................................................................. AR AR
1 2021294 Shim (0.007 in.) (0.20 mm) ............................................................................. AR AR
1 2021295 Shim (0.011 in.) (0.30 mm) ............................................................................. AR AR
1 2021296 Shim (0.015 in.) (0.40 mm) ............................................................................. AR AR
1 2021298 Shim (0.019 in.) (0.50 mm) ............................................................................. AR AR
2 2022352 Roller Bearing ................................................................................................. 2 2
3 2021299 Oil Seal............................................................................................................ 1 1
4 2021300 Bearing ............................................................................................................ 1 1
5 2023923 Gear ................................................................................................................ .. 1
5 2023922 Gear ................................................................................................................ 1 ..
6 a 2021912 Nut................................................................................................................... 1 1
6 b 2026862 Nut................................................................................................................... 1 1
7 a 2021303 Nut................................................................................................................... 1 1
7 b 2026861 Nut................................................................................................................... 1 1
8 a 2021305 Lockwasher ..................................................................................................... 1 1
9 2021914 Washer ............................................................................................................ 1 1
10 2023920 Shaft (Reverse) ............................................................................................... 1 1
11 2021915 Plug ................................................................................................................. 1 1
12 2023975 Bearing ............................................................................................................ 1 1
13 2021318 Bearing ............................................................................................................ 1 1
14 2023941 Gear (Reverse)................................................................................................ 1 1
15 2021320 Washer ............................................................................................................ 1 1
16 2021321 Snap Ring........................................................................................................ 1 1
17 1374796 Snap Ring........................................................................................................ 2 2
18 2023917 Gear Pump (☞ Figure 5-8) ............................................................................ 1 1
19 292515 Capscrew ........................................................................................................ 2 2
20 292682 Lockwasher ..................................................................................................... 2 2
21 b 2026860 Gear Set .......................................................................................................... 1 1
21 a 2021283 Gear Service Kit .............................................................................................. 1 1
996405 Transmission Kit (Includes Items 1-4, 7-8, 12-13, 16) ......................................... 1 1
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 87263
b S/N PENDING PER ECN 87263 ⇒
TRANSMISSION GEARS
(S/N PENDING PER ECN 76829-10⇒)
2043260 Transmission................................................................................................................ 1
2043261 Transmission................................................................................................................ 1
1 2021293 Shim (0.003 in.) ....................................................................................................... AR
1 2021294 Shim (0.007 in.) ....................................................................................................... AR
1 2021295 Shim (0.011 in.) ....................................................................................................... AR
1 2021296 Shim (0.015 in.) ....................................................................................................... AR
1 2021298 Shim (0.019 in.) ....................................................................................................... AR
2 2022352 Roller Bearing ......................................................................................................... 2
3 2021299 Oil Seal.................................................................................................................... 1
4 2021300 Bearing .................................................................................................................... 1
5 2023923 Gear (Output) .......................................................................................................... 1
6 a 2021912 Nut........................................................................................................................... 1
6 b 2026862 Nut........................................................................................................................... 1
7 a 2021303 Nut........................................................................................................................... 1
7 b 2026861 Nut........................................................................................................................... 1
8 a 2021305 Lockwasher ............................................................................................................. 1
9 2021914 Washer .................................................................................................................... 1
10 2045286 Shaft (Reverse) ....................................................................................................... 1
11 2021915 Plug ......................................................................................................................... 1
12 2023975 Bearing .................................................................................................................... 1
13 2021318 Bearing .................................................................................................................... 1
14 2023941 Gear (Reverse)........................................................................................................ 1
15 2021320 Washer .................................................................................................................... 1
16 2021321 Snap Ring................................................................................................................ 1
17 1374796 Snap Ring................................................................................................................ 2
18 c 2043271 Hydraulic Clutch Assembly...................................................................................... 1
19 292515 Capscrew ................................................................................................................ 2
20 292682 Lockwasher ............................................................................................................. 2
21 a 2021283 Gear Service Kit ...................................................................................................... 1
21 b 2026860 Gear Set .................................................................................................................. 1
FOOTNOTES:
a ⇒ S/N A810B-4340
b S/N A810B-4341 ⇒
c S/N PENDING PER ECN 76829-10 ⇒
HYDRAULIC CLUTCH
(⇒S/N D001H-2628)
KEY:
A: Gasoline and LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
HYDRAULIC CLUTCH
(S/N D001H-2629⇔S/N PENDING PER ECN 86576)
HYDRAULIC CLUTCH
(S/N PENDING PER ECN 86576⇔S/N PENDING PER ECN 87177)
HYDRAULIC CLUTCH
(S/N PENDING PER ECN 87177⇔S/N PENDING PER ECN 76829-10)
HYDRAULIC CLUTCH
(S/N PENDING PER ECN 76829-10⇒)
SOLENOID VALVE
CONTROL VALVE
(⇒S/N D001H-2628)
CONTROL VALVE
(S/N D001H-2629⇔S/N D001H-3016)
CONTROL VALVE
(S/N D001H-3017⇔S/N PENDING PER ECN 77425)
CONTROL VALVE
(S/N PENDING PER ECN 77425⇒)
KEY:
A: Gasoline and LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Diesel
b Gasoline and LPG
c ⇒ S/N PENDING PER ECN 87303
d S/N PENDING PER ECN 87303 ⇒
e ⇒ S/N PENDING PER ECN 87829
f S/N PENDING PER ECN 87829 ⇒
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 76829-10
b S/N PENDING PER ECN 76829-10 ⇒
5-45
UNIT CODE D001
NORTH AMERICA 03/2002
DRIVE AXLE
FOOTNOTES:
a ⇒ D/B 06/1997
b D/B 06/1997 ⇒
1 2314259 Filter............................................................................................................................. 1
2 2021462 Bracket......................................................................................................................... 1
3 287805 Capscrew..................................................................................................................... 2
4 292681 Lockwasher.................................................................................................................. 2
5 130845 Clamp .......................................................................................................................... 6
6 2021463 Hose ............................................................................................................................ 1
7 2021464 Hose ............................................................................................................................ 1
8 2022826 Hose ............................................................................................................................ 1
9 397676 Strap Clamp................................................................................................................. 1
10 2021404 Filter............................................................................................................................. 1
11 2021405 Fitting........................................................................................................................... 1
12 2021406 Hose ............................................................................................................................ 1
13 2022829 Clamp .......................................................................................................................... 2
14 2023719 Fitting........................................................................................................................... 1
15 2021407 Tube ............................................................................................................................. 1
16 176454 Clamp .......................................................................................................................... 1
17 287851 Capscrew..................................................................................................................... 1
18 137852 Strap Clamp................................................................................................................. 1
1 2314259 Filter............................................................................................................................. 1
2 2021462 Bracket......................................................................................................................... 1
3 302269 Bolt .............................................................................................................................. 2
4 292681 Lockwasher.................................................................................................................. 2
5 2022724 Clamp .......................................................................................................................... AR
5 2022723 Clamp .......................................................................................................................... 8
6 2023932 Hose ............................................................................................................................ 1
7 2021464 Hose ............................................................................................................................ 1
8 2022826 Hose ............................................................................................................................ 1
9 2022545 Strap Clamp................................................................................................................. 1
10 397676 Strap Clamp................................................................................................................. 1
11 2021404 Filter............................................................................................................................. 1
12 2021405 Fitting........................................................................................................................... 1
13 2021406 Hose ............................................................................................................................ 1
14 2022829 Clamp .......................................................................................................................... 2
15 2021423 Fitting........................................................................................................................... 1
16 2021407 Tube ............................................................................................................................. 1
2314259 Filter............................................................................................................................. 1
2 2022883 Bracket......................................................................................................................... 1
3 287805 Capscrew..................................................................................................................... 2
4 292681 Lockwasher.................................................................................................................. 2
5 130845 Clamp .......................................................................................................................... 6
6 2022884 Hose ............................................................................................................................ 1
7 2022885 Hose ............................................................................................................................ 1
8 2022886 Hose ............................................................................................................................ 1
9 397676 Strap Clamp................................................................................................................. 2
10 2021404 Filter............................................................................................................................. 1
11 b 2026591 Fitting........................................................................................................................... 1
11 a 2026518 Fitting........................................................................................................................... 1
12 2021406 Hose ............................................................................................................................ 1
13 2022829 Clamp .......................................................................................................................... 2
14 2023719 Fitting........................................................................................................................... 2
15 2021407 Tube ............................................................................................................................. 1
16 176454 Clamp .......................................................................................................................... 1
17 287851 Capscrew..................................................................................................................... 1
18 2026522 Hose ............................................................................................................................ 1
19 2026519 Fitting........................................................................................................................... 1
20 2026520 Tube ............................................................................................................................. 1
21 2022723 Clamp .......................................................................................................................... 2
22 2026583 Fitting........................................................................................................................... 1
FOOTNOTES:
a ⇒ S/N D001H-3149
b S/N D001H-3150 ⇒
END PLATE
5-56
UNIT CODE D001
03/2002 NORTH AMERICA
6 STEERING SYSTEM
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 6
STEERING SYSTEM
DESCRIPTION PAGE
STEERING COLUMN
1 136985 Capscrew..................................................................................................................... 4
2 292682 Lockwasher.................................................................................................................. 4
3 136692 Nut ............................................................................................................................... 4
4 1337043 Bracket......................................................................................................................... 1
5 1329250 Steering Wheel ............................................................................................................ 1
6 1347135 Horn Button ................................................................................................................. 1
7 1343573 Bracket......................................................................................................................... 1
8 1378600 Spring .......................................................................................................................... 1
9 1335987 Shaft ............................................................................................................................ 1
10 1335967 Plate ............................................................................................................................ 2
11 136749 Capscrew..................................................................................................................... 4
12 292681 Lockwasher.................................................................................................................. 4
13 296010 Capscrew..................................................................................................................... 1
14 302400 Locknut ........................................................................................................................ 1
15 1364271 Latch ............................................................................................................................ 1
16 1343607 Pin ............................................................................................................................... 1
17 15212 Cotter Pin..................................................................................................................... 1
18 1343574 Knob ............................................................................................................................ 1
19 296472 Screw........................................................................................................................... 2
20 1343572 Rod .............................................................................................................................. 1
21 1343537 Spring .......................................................................................................................... 1
22 320155 Washer ........................................................................................................................ 1
23 1367881 Guide (☞ Figure 6-2) ................................................................................................. 1
24 221706 Nut ............................................................................................................................... 4
25 15155 Lockwasher.................................................................................................................. 4
26 18515 Washer ........................................................................................................................ 8
27 1337196 Screw........................................................................................................................... 6
28 ace 1343605 Cover (Upper) .............................................................................................................. 1
28 ade 1335879 Cover (Upper) .............................................................................................................. 1
28 f 1376744 Cover (Upper) .............................................................................................................. 1
29 ade 1335880 Cover (Lower) .............................................................................................................. 1
29 ace 1343606 Cover (Lower) .............................................................................................................. 1
29 f 1376745 Cover (Lower) .............................................................................................................. 1
30 bc 1343597 Plug ............................................................................................................................. 1
31 df 1376743 Plug ............................................................................................................................. 1
FOOTNOTES:
a Forward/Reverse
b Monotrol Pedal
c With Turn Signal
d Without Turn Signal
e ⇒ S/N D001H-3567
f S/N D001H-3568 ⇒
STEERING AXLE
STEERING CYLINDER
(⇒S/N PENDING PER ECN 87046-01)
FOOTNOTES:
a ⇒ D/B 07/1997
b D/B 07/1997 ⇒
STEERING CYLINDER
(S/N PENDING PER ECN 87046-01⇒)
6-12
UNIT CODE D001
03/2002 NORTH AMERICA
7 BRAKE SYSTEM
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 7
BRAKE SYSTEM
DESCRIPTION PAGE
BRAKE ASSEMBLY
D/B 06/1997⇒ ................................................................................................................................................ 7-14
⇒D/B 06/1997 ................................................................................................................................................ 7-10
BRAKE LINES ...................................................................................................................................................... 7-8
BRAKE LINKAGE
⇒S/N D001H-2628 ........................................................................................................................................... 7-2
S/N D001H-2629⇒ ........................................................................................................................................... 7-4
MASTER CYLINDER ......................................................................................................................................... 7-20
PARK BRAKE LEVER ........................................................................................................................................ 7-18
BRAKE LINKAGE
(⇒S/N D001H-2628)
BRAKE LINKAGE
(S/N D001H-2629⇒)
BRAKE LINKAGE
(S/N D001H-2629⇒)
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 76829-17
b S/N PENDING PER ECN 76829-17⇔S/N PENDING PER ECN 77556
c S/N PENDING PER ECN 77556 ⇒
7-7
UNIT CODE D001
NORTH AMERICA 03/2002
BRAKE LINES
FOOTNOTES:
a ⇒ D/B 06/1997
b D/B 06/1997 ⇒
BRAKE ASSEMBLY
(⇒D/B 06/1997)
KEY:
A: Left Hand
B: Right Hand
QTY
ITEM PART NO. DESCRIPTION A B
2026299 Brake Assembly ................................................................................................... 1 ..
2026300 Brake Assembly ................................................................................................... .. 1
1 1367759 Backing Plate .................................................................................................. 1 ..
1 1367760 Backing Plate .................................................................................................. .. 1
2 .. . . . Brake Shoe...................................................................................................... 2 2
3 1367764 Bolt .................................................................................................................. 2 2
4 1367765 Plug ................................................................................................................. 1 1
5 .. . . . Adjuster ........................................................................................................... .. 1
5 .. . . . Adjuster ........................................................................................................... 1 ..
6 1367769 Lever................................................................................................................ 1 ..
6 1367770 Lever................................................................................................................ .. 1
7 1367771 Strut................................................................................................................. 1 1
8 .. . . . Pin ................................................................................................................... 1 1
9 .. . . . Retainer........................................................................................................... 1 1
10 1367774 Spring .............................................................................................................. 2 2
11 .. . . . Spring .............................................................................................................. 2 2
12 .. . . . Pin ................................................................................................................... 2 2
13 .. . . . Sleeve.............................................................................................................. 1 1
14 .. . . . Washer ............................................................................................................ 3 3
15 1367854 Plate ................................................................................................................ 1 1
16 1367855 Plug ................................................................................................................. 1 1
17 .. . . . Lever................................................................................................................ .. 1
17 .. . . . Lever................................................................................................................ 1 ..
18 .. . . . Pawl................................................................................................................. 1 1
19 .. . . . Spring .............................................................................................................. 1 1
20 .. . . . Spring .............................................................................................................. 1 1
21 1367862 Spring .............................................................................................................. 1 1
22 2026767 Cable ............................................................................................................... 1 ..
22 2026768 Cable ............................................................................................................... .. 1
23 1367865 Retainer........................................................................................................... 1 1
24 1367762 Wheel Cylinder ................................................................................................ 1 ..
24 1367763 Wheel Cylinder ................................................................................................ .. 1
25 .. . . . Piston .......................................................................................................... 2 2
26 .. . . . Cup ............................................................................................................. 2 2
27 .. . . . Spring.......................................................................................................... 1 1
28 .. . . . Boot............................................................................................................. 2 2
29 1367870 Screw (Bleed).............................................................................................. 1 1
30 1367871 Cup ............................................................................................................. 1 1
31 .. . . . Tube Seat .................................................................................................... 1 1
32 .. . . . Body............................................................................................................ 1 1
33 1367875 Piston Rod .................................................................................................. 2 2
34 3003343 Brake Cleaner...................................................................................................... AR AR
BRAKE ASSEMBLY
(⇒D/B 06/1997)
QTY
ITEM PART NO. DESCRIPTION A B
7-13
UNIT CODE D001
NORTH AMERICA 03/2002
BRAKE ASSEMBLY
(D/B 06/1997⇒)
KEY:
A: Left Hand
B: Right Hand
QTY
ITEM PART NO. DESCRIPTION A B
2026759 Brake Assembly ................................................................................................... 1 ..
2026760 Brake Assembly ................................................................................................... .. 1
1 2026773 Plate (Back)..................................................................................................... .. 1
1 2026774 Plate (Back)..................................................................................................... 1 ..
2 .. . . . Brake Shoe...................................................................................................... 2 2
3 2026776 Bolt .................................................................................................................. 2 2
4 .. . . . Adjuster Assembly........................................................................................... .. 1
4 .. . . . Adjuster Assembly........................................................................................... 1 ..
5 .. . . . Adjuster Spring................................................................................................ 1 1
6 2026777 Lever................................................................................................................ .. 1
6 2026778 Lever................................................................................................................ 1 ..
7 2026779 Pin ................................................................................................................... 1 1
8 2026780 Strut................................................................................................................. 1 1
9 2026781 Snap Ring........................................................................................................ 2 ..
10 2026782 Spring .............................................................................................................. 2 2
11 .. . . . Shoe Hold Down Spring .................................................................................. 2 2
12 .. . . . Washer ............................................................................................................ 2 2
13 .. . . . Washer (Lower) ............................................................................................... 1 1
14 .. . . . Pin ................................................................................................................... 2 2
15 1367854 Plate ................................................................................................................ 1 1
16 1367855 Plug ................................................................................................................. 1 1
17 .. . . . Lever................................................................................................................ .. 1
17 .. . . . Lever................................................................................................................ 1 ..
18 .. . . . Stop (Lever)..................................................................................................... 1 1
19 .. . . . Spring .............................................................................................................. 1 1
20 2026783 Spring .............................................................................................................. 1 1
21 2026767 Cable ............................................................................................................... 1 ..
21 2026768 Cable ............................................................................................................... .. 1
22 2026775 Wheel Cylinder ................................................................................................ 1 1
23 .. . . . Piston .......................................................................................................... 2 2
24 .. . . . Cup ............................................................................................................. 2 2
25 .. . . . Spring.......................................................................................................... 1 1
26 1367869 Boot............................................................................................................. 2 2
27 .. . . . Dust Cover .................................................................................................. 2 2
28 1367875 Piston Rod .................................................................................................. 2 2
29 1367870 Screw (Bleed).............................................................................................. 1 1
30 1367871 Cup ............................................................................................................. 1 1
31 .. . . . Tube ............................................................................................................ 1 1
32 .. . . . Cylinder Body.............................................................................................. 1 1
33 .. . . . Plug............................................................................................................. 1 1
34 3003343 Brake Cleaner...................................................................................................... AR AR
BRAKE ASSEMBLY
(D/B 06/1997⇒)
QTY
ITEM PART NO. DESCRIPTION A B
7-17
UNIT CODE D001
NORTH AMERICA 03/2002
FOOTNOTES:
a S/N D001H-2784 ⇒
MASTER CYLINDER
7-22
UNIT CODE D001
03/2002 NORTH AMERICA
8 HYDRAULIC SYSTEM
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 8
HYDRAULIC SYSTEM
DESCRIPTION PAGE
CONTROL VALVE
FOUR FUNCTION
DUAL RELIEF
⇒S/N D001H-3395.................................................................................................................................. 8-54
S/N D001H-3396⇒.................................................................................................................................. 8-58
SINGLE RELIEF
⇒S/N D001H-3395.................................................................................................................................. 8-46
S/N D001H-3396⇒.................................................................................................................................. 8-50
THREE FUNCTION
DUAL RELIEF
⇒S/N D001H-3395.................................................................................................................................. 8-34
S/N D001H-3396⇒.................................................................................................................................. 8-38
SINGLE RELIEF
⇒S/N D001H-3395.................................................................................................................................. 8-26
S/N D001H-3396⇒.................................................................................................................................. 8-30
CONTROL VALVE ATTACHING PARTS
FOUR FUNCTION
⇒S/N D001H-3395 ..................................................................................................................................... 8-42
S/N D001H-3396⇒ ..................................................................................................................................... 8-44
THREE FUNCTION
⇒S/N D001H-3395 ..................................................................................................................................... 8-18
S/N D001H-3396⇒ ..................................................................................................................................... 8-22
HYDRAULIC PUMP
DIESEL
⇒S/N D001H-3304 ..................................................................................................................................... 8-12
GASOLINE AND LPG
⇒S/N D001H-3304 ..................................................................................................................................... 8-10
S/N D001H-3305⇒ ..................................................................................................................................... 8-14
HYDRAULICS
⇒S/N D001H-2081 ........................................................................................................................................... 8-2
S/N D001H-2082⇒ ........................................................................................................................................... 8-6
PUMP DRIVE
DIESEL ........................................................................................................................................................... 8-17
GASOLINE AND LPG..................................................................................................................................... 8-16
TILT CYLINDER ................................................................................................................................................. 8-62
HYDRAULICS
(⇒S/N D001H-2081)
HYDRAULICS
(⇒S/N D001H-2081)
FOOTNOTES:
a S/N D001H-2629 ⇒
b S/N D001H-2784 ⇒
c ⇒ S/N PENDING PER ECN 87046-01
d S/N PENDING PER ECN 87046-01 ⇒
8-5
UNIT CODE D001
NORTH AMERICA 03/2002
HYDRAULICS
(S/N D001H-2082⇒)
HYDRAULICS
(S/N D001H-2082⇒)
FOOTNOTES:
a Diesel
b ⇒ S/N D001H-2350
c S/N D001H-2351 ⇒
d S/N D001H-2629 ⇒
e S/N D001H-2784 ⇒
f ⇒ S/N D001H-3304
g S/N D001H-3305 ⇒
h ⇒ S/N PENDING PER ECN 86496
i S/N PENDING PER ECN 86496 ⇒
HYDRAULICS
(S/N D001H-2082⇒)
j ⇒ S/N PENDING PER ECN 87046-01
k S/N PENDING PER ECN 87046-01 ⇒
HYDRAULIC PUMP
GASOLINE AND LPG
(⇒S/N D001H-3304)
FOOTNOTES:
a S/N D001H-2629 ⇒
HYDRAULIC PUMP
DIESEL
(⇒S/N D001H-3304)
HYDRAULIC PUMP
GASOLINE AND LPG
(S/N D001H-3305⇒)
KEY:
A: Gasoline and LPG
B: Diesel
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: Detented Lever
B: Non-Detented Lever
QTY
ITEM PART NO. DESCRIPTION A B
1 287503 Capscrew............................................................................................................. 3 3
2 292682 Lockwasher.......................................................................................................... 3 3
3 15177 Washer ................................................................................................................ 3 3
4 2020500 Lever .................................................................................................................... 1 1
5 2020501 Lever .................................................................................................................... 1 1
6 296160 Capscrew............................................................................................................. 6 6
7 313805 Nut ....................................................................................................................... 11 11
8 292680 Lockwasher.......................................................................................................... 6 6
9 2021862 Cover (Front)........................................................................................................ 1 1
10 2021863 Cover (Rear) ........................................................................................................ 1 1
11 2021864 Boot ..................................................................................................................... 1 1
12 2021865 Plate .................................................................................................................... 1 1
13 2022702 Screw................................................................................................................... 5 5
14 320156 Washer ................................................................................................................ 5 5
15 320157 Washer ................................................................................................................ 2 2
16 296165 Capscrew............................................................................................................. 5 5
17 292681 Lockwasher.......................................................................................................... 5 5
18 15175 Washer ................................................................................................................ 3 3
19 2023309 Control Valve (☞ Figure 8-10) ........................................................................... 1 1
19 2023354 Control Valve (☞ Figure 8-12) ........................................................................... 1 1
20 2021867 Bracket................................................................................................................. 1 ..
21 2020503 Lever .................................................................................................................... 1 ..
22 2021823 Yoke ..................................................................................................................... 2 3
23 2022912 Pivot..................................................................................................................... 1 ..
24 2022796 Bushing................................................................................................................ 6 6
25 2021810 Bushing................................................................................................................ 1 ..
26 2021813 Pin ....................................................................................................................... 1 ..
27 2021815 Link ...................................................................................................................... 2 3
28 2021816 Link ...................................................................................................................... 1 ..
29 2021817 Pin ....................................................................................................................... 6 6
30 2021818 Cotter Pin............................................................................................................. 6 6
31 320155 Washer ................................................................................................................ 6 6
32 2022911 Yoke ..................................................................................................................... 1 ..
33 2021852 Pin ....................................................................................................................... 1 ..
34 175861 Spring .................................................................................................................. 1 ..
35 302427 Pin ....................................................................................................................... 1 ..
36 2021860 Shim .................................................................................................................... AR ..
37 296417 Lockwasher.......................................................................................................... 1 ..
38 296128 Nut ....................................................................................................................... 3 ..
39 287817 Capscrew............................................................................................................. 1 ..
40 296417 Lockwasher.......................................................................................................... 1 ..
41 2021856 Bracket................................................................................................................. 1 ..
42 2311502 Shim (0.015 in.) ................................................................................................... AR ..
43 2021866 Bracket................................................................................................................. .. 1
44 2020502 Lever .................................................................................................................... .. 1
QTY
ITEM PART NO. DESCRIPTION A B
8-21
UNIT CODE D001
NORTH AMERICA 03/2002
KEY:
A: Detented Lever
B: Non-Detented Lever
QTY
ITEM PART NO. DESCRIPTION A B
1 287503 Capscrew............................................................................................................. 3 3
2 292682 Lockwasher.......................................................................................................... 3 3
3 15177 Washer ................................................................................................................ 3 3
4 2020500 Lever .................................................................................................................... 1 1
5 2020501 Lever .................................................................................................................... 1 1
6 296160 Capscrew............................................................................................................. 6 6
7 313805 Nut ....................................................................................................................... 11 11
8 292680 Lockwasher.......................................................................................................... 6 6
9 2021862 Cover (Front)........................................................................................................ 1 1
10 2021863 Cover (Rear) ........................................................................................................ 1 1
11 2021864 Boot ..................................................................................................................... 1 1
12 2021865 Plate .................................................................................................................... 1 1
13 2022702 Screw................................................................................................................... 5 5
14 320156 Washer ................................................................................................................ 5 5
15 320157 Washer ................................................................................................................ 2 2
16 296165 Capscrew............................................................................................................. 5 5
17 292681 Lockwasher.......................................................................................................... 5 5
18 15175 Washer ................................................................................................................ 3 3
19 2026063 Valve (Control) (☞ Figure 8-11) ......................................................................... 1 1
19 2026506 Control Valve (☞ Figure 8-13) ........................................................................... 1 1
20 2021867 Bracket................................................................................................................. 1 ..
21 2020503 Lever .................................................................................................................... 1 ..
22 2021823 Yoke ..................................................................................................................... 2 3
23 2022912 Pivot..................................................................................................................... 1 ..
24 2022796 Bushing................................................................................................................ 6 6
25 2021810 Bushing................................................................................................................ 1 ..
26 2021813 Pin ....................................................................................................................... 1 ..
27 2021815 Link ...................................................................................................................... 2 3
28 2021816 Link ...................................................................................................................... 1 ..
29 2021817 Pin ....................................................................................................................... 6 6
30 2021818 Cotter Pin............................................................................................................. 6 6
31 320155 Washer ................................................................................................................ 6 6
32 2022911 Yoke ..................................................................................................................... 1 ..
33 2021852 Pin ....................................................................................................................... 1 ..
34 175861 Spring .................................................................................................................. 1 ..
35 302427 Pin ....................................................................................................................... 1 ..
36 2021860 Shim .................................................................................................................... AR ..
37 296417 Lockwasher.......................................................................................................... 1 ..
38 296128 Nut ....................................................................................................................... 3 ..
39 287817 Capscrew............................................................................................................. 1 ..
40 296417 Lockwasher.......................................................................................................... 1 ..
41 2021856 Bracket................................................................................................................. 1 ..
42 2311502 Shim (0.015 in.) ................................................................................................... AR ..
43 2021866 Bracket................................................................................................................. .. 1
44 2020502 Lever .................................................................................................................... .. 1
QTY
ITEM PART NO. DESCRIPTION A B
8-25
UNIT CODE D001
NORTH AMERICA 03/2002
CONTROL VALVE
THREE FUNCTION
SINGLE RELIEF
(⇒S/N D001H-3395)
CONTROL VALVE
THREE FUNCTION
SINGLE RELIEF
(⇒S/N D001H-3395)
48 1368022 Collar................................................................................................................... 2
49 2023311 Tilt Spool Section .................................................................................................... 1
50 1368028 Plug Kit................................................................................................................ 1
51 1368018 O-Ring................................................................................................................. 2
52 2022191 O-Ring................................................................................................................. 1
53 .. . . . Spool................................................................................................................... 1
54 1368022 Collar................................................................................................................... 2
55 1368023 Spring.................................................................................................................. 1
56 1368007 Retainer .............................................................................................................. 1
57 1368024 Cap ..................................................................................................................... 1
58 1368029 Washer................................................................................................................ 1
59 2022208 Screw .................................................................................................................. 1
60 1368026 Screw .................................................................................................................. 2
61 2022210 O-Ring................................................................................................................. 1
62 .. . . . Spool................................................................................................................... 1
63 1368030 Plug..................................................................................................................... 1
64 1368031 Spring.................................................................................................................. 1
65 1368043 Spool Section (Auxiliary) ......................................................................................... 1
66 1368028 Plug Kit................................................................................................................ 1
67 1368018 O-Ring................................................................................................................. 2
68 2022191 O-Ring................................................................................................................. 1
69 .. . . . Spool................................................................................................................... 1
70 1368022 Collar................................................................................................................... 2
71 1368023 Spring.................................................................................................................. 1
72 1368007 Retainer .............................................................................................................. 1
73 1368024 Cap ..................................................................................................................... 1
74 1368025 Washer................................................................................................................ 1
75 296009 Capscrew ............................................................................................................ 1
76 1368026 Screw .................................................................................................................. 2
1368127 Seal Kit (Includes Items 21, 24-25, 28-31, 34, 39-40, 51-52, 61, 67-68)..................... 1
8-29
UNIT CODE D001
NORTH AMERICA 03/2002
CONTROL VALVE
THREE FUNCTION
SINGLE RELIEF
(S/N D001H-3396⇒)
CONTROL VALVE
THREE FUNCTION
SINGLE RELIEF
(S/N D001H-3396⇒)
44 .. . . . Spool................................................................................................................... 1
45 1368018 O-Ring................................................................................................................. 2
46 2022191 O-Ring................................................................................................................. 1
47 2022192 O-Ring................................................................................................................. 1
48 1368019 Plug..................................................................................................................... 1
49 1368020 Valve (Check)...................................................................................................... 1
50 1368021 Spring.................................................................................................................. 1
51 1368022 Collar................................................................................................................... 2
52 1368023 Spring.................................................................................................................. 1
53 1383683 Retainer .............................................................................................................. 1
54 1368024 Cap ..................................................................................................................... 1
55 1368025 Washer................................................................................................................ 1
56 296009 Capscrew ............................................................................................................ 1
57 1345711 Bolt...................................................................................................................... 2
58 1368040 Bracket (LH)................................................................................................................. 1
59 2021331 Bracket (RH) ................................................................................................................ 1
60 1383682 Capscrew..................................................................................................................... 4
2026069 Seal Kit (Includes Items 8, 14, 16, 20, 32, 35)............................................................. 1
1368028 Plug Kit (Includes Items 15-18, 47-50) ........................................................................ 1
8-33
UNIT CODE D001
NORTH AMERICA 03/2002
CONTROL VALVE
THREE FUNCTION
DUAL RELIEF
(⇒S/N D001H-3395)
CONTROL VALVE
THREE FUNCTION
DUAL RELIEF
(⇒S/N D001H-3395)
1368127 Seal Kit (Includes Items 21, 24-25, 28-31, 34, 39-40, 52-53, 62, 69-71, 73-74) ......... 1
2314134 Seal Kit (Includes Items 28-31) ................................................................................... 1
1368028 Plug Kit (Includes Items 34-37) ................................................................................... 1
8-37
UNIT CODE D001
NORTH AMERICA 03/2002
CONTROL VALVE
THREE FUNCTION
DUAL RELIEF
(S/N D001H-3396⇒)
CONTROL VALVE
THREE FUNCTION
DUAL RELIEF
(S/N D001H-3396⇒)
44 .. . . . Spool................................................................................................................... 1
45 1368018 O-Ring................................................................................................................. 2
46 2022191 O-Ring................................................................................................................. 1
47 2022192 O-Ring................................................................................................................. 1
48 1368019 Plug..................................................................................................................... 1
49 1368020 Valve (Check)...................................................................................................... 1
50 1368021 Spring.................................................................................................................. 1
51 1368022 Collar................................................................................................................... 2
52 1368023 Spring.................................................................................................................. 1
53 1383683 Retainer .............................................................................................................. 2
54 1368024 Cap ..................................................................................................................... 1
55 1368025 Washer................................................................................................................ 1
56 1345711 Bolt...................................................................................................................... 1
57 296009 Capscrew ............................................................................................................ 2
58 1368032 O-Ring ..................................................................................................................... 1
59 1368033 Back-Up Ring .......................................................................................................... 1
60 2022217 O-Ring ..................................................................................................................... 1
61 1368034 Plug ......................................................................................................................... 1
62 1368040 Bracket (LH)................................................................................................................. 1
63 2021331 Bracket (RH) ................................................................................................................ 1
64 1383682 Capscrew..................................................................................................................... 2
2026069 Seal Kit (Includes Items 8, 14, 16, 20, 32, 35)............................................................. 1
1368028 Plug Kit (Includes Items 16-19, 45-48) ........................................................................ 1
1368035 Plug Kit (Includes Items 56-59) ................................................................................... 1
8-41
UNIT CODE D001
NORTH AMERICA 03/2002
1 287503 Capscrew..................................................................................................................... 3
2 292682 Lockwasher.................................................................................................................. 3
3 15177 Washer ........................................................................................................................ 3
4 2020500 Lever ............................................................................................................................ 1
5 2020501 Lever ............................................................................................................................ 1
6 296160 Capscrew..................................................................................................................... 6
7 313805 Nut ............................................................................................................................... 11
8 292680 Lockwasher.................................................................................................................. 6
9 2021862 Cover (Front)................................................................................................................ 1
10 2021863 Cover (Rear) ................................................................................................................ 1
11 2021864 Boot ............................................................................................................................. 1
12 2021865 Plate ............................................................................................................................ 1
13 2022702 Screw........................................................................................................................... 5
14 320156 Washer ........................................................................................................................ 5
15 320157 Washer ........................................................................................................................ 2
16 296165 Capscrew..................................................................................................................... 5
17 292681 Lockwasher.................................................................................................................. 5
18 15175 Washer ........................................................................................................................ 3
19 2023310 Control Valve (☞ Figure 8-16) ................................................................................... 1
19 2023355 Control Valve (☞ Figure 8-18) ................................................................................... 1
20 2021867 Bracket......................................................................................................................... 1
21 2020503 Lever ............................................................................................................................ 1
22 2021823 Yoke ............................................................................................................................. 2
23 2022912 Pivot............................................................................................................................. 1
24 2022796 Bushing........................................................................................................................ 6
25 2021810 Bushing........................................................................................................................ 1
26 2021813 Pin ............................................................................................................................... 1
27 2021815 Link .............................................................................................................................. 2
28 2021816 Link .............................................................................................................................. 2
29 2021817 Pin ............................................................................................................................... 8
30 2021818 Cotter Pin..................................................................................................................... 8
31 320155 Washer ........................................................................................................................ 8
32 2022910 Yoke ............................................................................................................................. 1
33 2021851 Pin ............................................................................................................................... 1
34 175861 Spring .......................................................................................................................... 1
35 302427 Pin ............................................................................................................................... 1
36 2021860 Shim ............................................................................................................................ AR
37 320159 Washer ........................................................................................................................ 1
38 296128 Nut ............................................................................................................................... 3
39 2311502 Shim (0.015 in.) ........................................................................................................... AR
40 2021809 Bushing........................................................................................................................ 4
1 287503 Capscrew..................................................................................................................... 3
2 292682 Lockwasher.................................................................................................................. 3
3 15177 Washer ........................................................................................................................ 3
4 2020500 Lever ............................................................................................................................ 1
5 2020501 Lever ............................................................................................................................ 1
6 296160 Capscrew..................................................................................................................... 6
7 313805 Nut ............................................................................................................................... 11
8 292680 Lockwasher.................................................................................................................. 6
9 2021862 Cover (Front)................................................................................................................ 1
10 2021863 Cover (Rear) ................................................................................................................ 1
11 2021864 Boot ............................................................................................................................. 1
12 2021865 Plate ............................................................................................................................ 1
13 2022702 Screw........................................................................................................................... 5
14 320156 Washer ........................................................................................................................ 5
15 320157 Washer ........................................................................................................................ 2
16 296165 Capscrew..................................................................................................................... 5
17 292681 Lockwasher.................................................................................................................. 5
18 15175 Washer ........................................................................................................................ 3
19 2026065 Valve (Control) (☞ Figure 8-17) ................................................................................. 1
19 2026507 Control Valve (☞ Figure 8-19) ................................................................................... 1
20 2021867 Bracket......................................................................................................................... 1
21 2020503 Lever ............................................................................................................................ 1
22 2021823 Yoke ............................................................................................................................. 2
23 2022912 Pivot............................................................................................................................. 1
24 2022796 Bushing........................................................................................................................ 6
25 2021810 Bushing........................................................................................................................ 1
26 2021813 Pin ............................................................................................................................... 1
27 2021815 Link .............................................................................................................................. 2
28 2021816 Link .............................................................................................................................. 2
29 2021817 Pin ............................................................................................................................... 8
30 2021818 Cotter Pin..................................................................................................................... 8
31 320155 Washer ........................................................................................................................ 8
32 2022910 Yoke ............................................................................................................................. 1
33 2021851 Pin ............................................................................................................................... 1
34 175861 Spring .......................................................................................................................... 1
35 302427 Pin ............................................................................................................................... 1
36 2021860 Shim ............................................................................................................................ AR
37 320159 Washer ........................................................................................................................ 1
38 296128 Nut ............................................................................................................................... 3
39 2311502 Shim (0.015 in.) ........................................................................................................... AR
40 2021809 Bushing........................................................................................................................ 4
41 17222 Fitting........................................................................................................................... 2
42 16558 Fitting........................................................................................................................... 2
43 1377372 Hose ............................................................................................................................ 1
44 1377371 Hose ............................................................................................................................ 1
45 1377374 Hose ............................................................................................................................ 1
46 1377373 Hose ............................................................................................................................ 1
CONTROL VALVE
FOUR FUNCTION
SINGLE RELIEF
(⇒S/N D001H-3395)
CONTROL VALVE
FOUR FUNCTION
SINGLE RELIEF
(⇒S/N D001H-3395)
1368128 Seal Kit (Includes Items 21, 24-25, 28-31, 34, 39-40, 51-52, 61, 68-70, 72-73) ......... 1
1368028 Plug Kit (Includes Items 34-37) ................................................................................... 1
8-49
UNIT CODE D001
NORTH AMERICA 03/2002
CONTROL VALVE
FOUR FUNCTION
SINGLE RELIEF
(S/N D001H-3396⇒)
CONTROL VALVE
FOUR FUNCTION
SINGLE RELIEF
(S/N D001H-3396⇒)
44 .. . . . Spool................................................................................................................... 2
45 1368018 O-Ring................................................................................................................. 4
46 2022191 O-Ring................................................................................................................. 2
47 2022192 O-Ring................................................................................................................. 2
48 1368019 Plug..................................................................................................................... 2
49 1368020 Valve (Check)...................................................................................................... 2
50 1368021 Spring.................................................................................................................. 2
51 1368022 Collar................................................................................................................... 4
52 1368023 Spring.................................................................................................................. 2
53 1383683 Retainer .............................................................................................................. 2
54 1368024 Cap ..................................................................................................................... 2
55 1368025 Washer................................................................................................................ 2
56 1345711 Bolt...................................................................................................................... 4
57 296009 Capscrew ............................................................................................................ 2
58 2037369 Back-Up Ring.................................................................................................. 1
58 2037372 O-Ring ............................................................................................................ 1
58 2022205 Valve (Relief)....................................................................................................... 2
58 2037371 O-Ring ............................................................................................................ 1
58 2022569 Seal Kit ........................................................................................................... 1
58 2037370 O-Ring ............................................................................................................ 1
59 1368032 O-Ring ..................................................................................................................... 2
60 1368033 Back-Up Ring .......................................................................................................... 2
61 2022217 O-Ring ..................................................................................................................... 2
62 1368034 Plug ......................................................................................................................... 2
63 1368040 Bracket (LH)................................................................................................................. 1
64 2021331 Bracket (RH) ................................................................................................................ 1
65 1383682 Capscrew..................................................................................................................... 4
2026070 Seal Kit (Includes Items 8, 14, 16, 20, 32, 35)............................................................. 1
1368028 Plug Kit (Includes Items 16-19, 47-50) ........................................................................ 1
1368035 Plug Kit (Includes Items 59-62) ................................................................................... 1
8-53
UNIT CODE D001
NORTH AMERICA 03/2002
CONTROL VALVE
FOUR FUNCTION
DUAL RELIEF
(⇒S/N D001H-3395)
CONTROL VALVE
FOUR FUNCTION
DUAL RELIEF
(⇒S/N D001H-3395)
1368128 Seal Kit (Includes Items 21, 24-25, 28-31, 34, 39-40, 52-53, 62, 69-71, 73-74) ......... 1
2314134 Seal Kit (Includes Items 28-31) ................................................................................... 1
1368028 Plug Kit (Includes Items 34-37) ................................................................................... 1
8-57
UNIT CODE D001
NORTH AMERICA 03/2002
CONTROL VALVE
FOUR FUNCTION
DUAL RELIEF
(S/N D001H-3396⇒)
CONTROL VALVE
FOUR FUNCTION
DUAL RELIEF
(S/N D001H-3396⇒)
49 1368019 Plug..................................................................................................................... 2
50 1368020 Valve (Check)...................................................................................................... 2
51 1368021 Spring.................................................................................................................. 2
52 1368022 Collar................................................................................................................... 4
53 1368023 Spring.................................................................................................................. 2
54 1383683 Retainer .............................................................................................................. 2
55 1368024 Cap ..................................................................................................................... 2
56 1368025 Washer................................................................................................................ 2
57 1345711 Bolt...................................................................................................................... 4
58 296009 Capscrew ............................................................................................................ 2
59 1368032 O-Ring ..................................................................................................................... 2
60 1368033 Back-Up Ring .......................................................................................................... 2
61 2022217 O-Ring ..................................................................................................................... 2
62 1368034 Plug ......................................................................................................................... 2
63 1368040 Bracket (LH)................................................................................................................. 1
64 2021331 Bracket (RH) ................................................................................................................ 1
65 1383682 Capscrew..................................................................................................................... 4
2026070 Seal Kit (Includes Items 8, 14, 16, 20, 32, 35)............................................................. 1
2314134 Seal Kit (Includes Item 4) ............................................................................................ 1
1368028 Plug Kit (Includes Items 16-19, 48-51) ........................................................................ 1
1368035 Plug Kit (Includes Items 59-62) ................................................................................... 1
8-61
UNIT CODE D001
NORTH AMERICA 03/2002
TILT CYLINDER
8-64
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 9
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-14
FORK
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-26
HEADER HOSE
FOUR FUNCTION
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-22
THREE FUNCTION
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-20
INNER MAST
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 9-4
LIFT
TWO STAGE LIMITED FREE-LIFT
⇒S/N A550L-1566 ........................................................................................................................................ 9-6
S/N A550L-1567⇒ ........................................................................................................................................ 9-8
LIFT CYLINDER
LEFT HAND
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-10
RIGHT HAND
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-12
LOAD BACKREST EXTENSION
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-16
MAST INSTALLATION
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-18
OUTER MAST
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 9-2
OUTER MAST
TWO STAGE LIMITED FREE-LIFT
1 a .. . . . Outer Mast................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 215212 Bearing Strip................................................................................................................ 2
4 131716 Shim (0.020 in.) ........................................................................................................... 4
5 104506 O-Ring ......................................................................................................................... 4
6 1353192 Load Roller ("B") (0,76 mm)......................................................................................... AR
6 1353193 Load Roller ("C") (1,52 mm) ........................................................................................ AR
6 1395169 Load Roller ("A") (Optional) ......................................................................................... 2
6 1395173 Load Roller ("A") (Standard) ........................................................................................ 2
6 1395175 Load Roller ("A") (Optional) ......................................................................................... 2
7 58901 Snap Ring.................................................................................................................... 2
8 129387 Shim (0.020 in.) ........................................................................................................... AR
FOOTNOTES:
a Refer to Table
INNER MAST
TWO STAGE LIMITED FREE-LIFT
1 a .. . . . Inner Mast.................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 1353192 Load Roller ("B") (0,76 mm)......................................................................................... AR
3 1353193 Load Roller ("C") (1,52 mm) ........................................................................................ AR
3 1395169 Load Roller ("A") (Optional) ......................................................................................... 2
3 1395173 Load Roller ("A") (Standard) ........................................................................................ 2
3 1395175 Load Roller ("A") (Optional) ......................................................................................... 2
4 58901 Snap Ring.................................................................................................................... 2
5 129387 Shim (0.020 in.) ........................................................................................................... AR
6 304526 Snap Ring.................................................................................................................... 2
7 b 1345183 Chain Sheave .............................................................................................................. 2
7 c 1379685 Chain Sheave Assembly.............................................................................................. 2
8 b 1345181 Sheave .................................................................................................................... 1
8 c 1378698 Sheave .................................................................................................................... 1
9 c 1378699 Bearing .................................................................................................................... 1
9 b 231020 Bearing .................................................................................................................... 1
10 c 37752 Snap Ring................................................................................................................ 1
10 b 37752 Snap Ring................................................................................................................ 2
11 d 1379707 Spacer ..................................................................................................................... 4
FOOTNOTES:
a Refer to Table
b ⇒ S/N A550L-1774
c S/N A550L-1775 ⇒
d S/N A550L-1775⇔S/N A550L-1786
LIFT
TWO STAGE LIMITED FREE-LIFT
(⇒S/N A550L-1566)
LIFT HEIGHT TO BOTTOM OF FORKS
DESCRIPTION 2591 mm 2892 mm 3192 mm
ITEM 1 2 3 4 (102 in.) (113.9 in.) (125.7 in.)
Mast A550 A550 A550
Group Number 2592 2892 3192
27 Chain 182332 182343 135634
FOOTNOTES:
a Refer to Table
LIFT
TWO STAGE LIMITED FREE-LIFT
(S/N A550L-1567⇒)
FOOTNOTES:
a Refer to Table
b ⇒ S/N A550L-1572
c S/N A550L-1573 ⇒
LIFT CYLINDER
LEFT HAND
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a Refer to Table
LIFT CYLINDER
RIGHT HAND
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a Refer to Table
CARRIAGE
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a ⇒ S/N A550L-2095
b S/N A550L-2096 ⇒
9-17
UNIT CODE D001
NORTH AMERICA 03/2002
MAST INSTALLATION
TWO STAGE LIMITED FREE-LIFT
HEADER HOSE
THREE FUNCTION
TWO STAGE LIMITED FREE-LIFT
1 a .. . . . Hose ............................................................................................................................ 2
2 1360508 Clamp .......................................................................................................................... 2
3 1360549 Spacer ......................................................................................................................... 1
4 292508 Capscrew..................................................................................................................... 4
5 1345412 Bracket (RH) ................................................................................................................ 1
6 313828 Nut ............................................................................................................................... 6
7 1363486 Bracket......................................................................................................................... 1
8 1360548 Stubshaft ..................................................................................................................... 1
9 1381595 Sheave......................................................................................................................... 1
10 1345190 Washer ........................................................................................................................ 2
11 313805 Nut ............................................................................................................................... 2
12 292533 Capscrew..................................................................................................................... 1
13 1360386 Clamp .......................................................................................................................... 1
14 292683 Lockwasher.................................................................................................................. 1
15 136704 Capscrew..................................................................................................................... 2
16 287816 Capscrew..................................................................................................................... 2
17 1353530 Clamp .......................................................................................................................... 4
18 1345348 Clamp .......................................................................................................................... 2
19 1375574 Strap ............................................................................................................................ 2
20 16558 Fitting........................................................................................................................... 1
20 16483 O-Ring ..................................................................................................................... 1
21 b 1377371 Hose ............................................................................................................................ 1
21 c 1377371 Hose ............................................................................................................................ 2
22 b 1377372 Hose ............................................................................................................................ 1
23 b 292681 Lockwasher.................................................................................................................. 1
24 b 2022830 Clamp .......................................................................................................................... 1
25 b 239503 Nut ............................................................................................................................... 3
26 17222 Fitting........................................................................................................................... 1
26 16483 O-Ring ..................................................................................................................... 1
27 c 129563 Strap Clamp................................................................................................................. 3
FOOTNOTES:
a Refer to Table
b ⇒ S/N PENDING PER ECN 72115-02
c S/N PENDING PER ECN 72115-02 ⇒
d ⇒ D/B 11/1998
e D/B 11/1998 ⇒
HEADER HOSE
FOUR FUNCTION
TWO STAGE LIMITED FREE-LIFT
1 a .. . . . Hose ............................................................................................................................ 4
2 1360549 Spacer ......................................................................................................................... 2
3 1360508 Clamp .......................................................................................................................... 4
4 b 292508 Capscrew..................................................................................................................... 8
5 1345412 Bracket (RH) ................................................................................................................ 1
5 1345413 Bracket (LH)................................................................................................................. 1
6 2022830 Clamp .......................................................................................................................... 1
7 313828 Nut ............................................................................................................................... 12
8 1363486 Bracket......................................................................................................................... 2
9 1360548 Stubshaft ..................................................................................................................... 2
10 1494017 Sheave......................................................................................................................... 2
11 1345190 Washer ........................................................................................................................ 4
12 313805 Nut ............................................................................................................................... 4
13 292533 Capscrew..................................................................................................................... 2
14 1360386 Clamp .......................................................................................................................... 2
15 292683 Lockwasher.................................................................................................................. 2
16 136704 Capscrew..................................................................................................................... 4
18 1353530 Clamp .......................................................................................................................... 8
19 1345348 Clamp .......................................................................................................................... 4
20 1375574 Strap ............................................................................................................................ 4
21 16558 Fitting........................................................................................................................... 2
21 16483 O-Ring ..................................................................................................................... 1
22 b 1377371 Hose ............................................................................................................................ 1
22 c 1377371 Hose ............................................................................................................................ 2
23 b 1377372 Hose ............................................................................................................................ 1
24 239503 Nut ............................................................................................................................... 3
25 b 239503 Nut ............................................................................................................................... 1
26 b 292681 Lockwasher.................................................................................................................. 1
27 b 320157 Washer ........................................................................................................................ 1
28 17222 Fitting........................................................................................................................... 2
28 16483 O-Ring ..................................................................................................................... 1
29 b 101625 Clamp .......................................................................................................................... 2
30 c 1377372 Hose ............................................................................................................................ 1
30 b 1377373 Hose ............................................................................................................................ 1
31 c 1377372 Hose ............................................................................................................................ 1
31 b 1377374 Hose ............................................................................................................................ 1
32 292681 Lockwasher.................................................................................................................. 1
HEADER HOSE
FOUR FUNCTION
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a Refer to Table
b ⇒ S/N PENDING PER ECN 72115-02
c S/N PENDING PER ECN 72115-02 ⇒
d ⇒ D/B 11/1998
e D/B 11/1998 ⇒
9-25
UNIT CODE D001
NORTH AMERICA 03/2002
FORK
TWO STAGE LIMITED FREE-LIFT
KEY:
A: Full Bottom Taper (40 mm x 100 mm)
B: Standard Taper (40 mm x 100 mm)
C: Standard Taper (40 mm x 80 mm)
QTY
ITEM PART NO. DESCRIPTION A B C
NOTE:
Other Fork Dimensions Available on Request, Contact Your Hyster Lift Truck Dealer.
9-28
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 10
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-26
FORK
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-40
FREE-LIFT
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-16
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-24
HEADER HOSE
FOUR FUNCTION
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10-36
THREE FUNCTION
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10-32
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 10-6
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 10-4
LOAD BACKREST EXTENSION
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-28
MAIN LIFT
THREE STAGE FULL FREE-LIFT
⇒S/N A554L-18550 .................................................................................................................................... 10-8
S/N A554L-1856⇒ .................................................................................................................................... 10-12
MAIN LIFT CYLINDER
LEFT HAND
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10-20
RIGHT HAND
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10-22
MAST INSTALLATION
THREE STAGE FULL FREE-LIFT ................................................................................................................ 10-30
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................. 10-2
OUTER MAST
THREE STAGE FULL FREE-LIFT
1 a .. . . . Outer Mast................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 215212 Bearing Strip................................................................................................................ 2
4 131716 Shim (0.020 in.) ........................................................................................................... 4
5 104506 O-Ring ......................................................................................................................... 4
6 1353192 Load Roller ("B") (0,76 mm)......................................................................................... AR
6 1353193 Load Roller ("C") (1,52 mm) ........................................................................................ AR
6 1395169 Load Roller ("A") (Optional) ......................................................................................... 2
6 1395173 Load Roller ("A") (Standard) ........................................................................................ 2
6 1395175 Load Roller ("A") (Optional) ......................................................................................... 2
7 58901 Snap Ring.................................................................................................................... 2
8 129387 Shim (0.020 in.) ........................................................................................................... AR
FOOTNOTES:
a Refer to Table
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
1 a .. . . . Intermediate Mast........................................................................................................ 1
2 1345216 Stubshaft ................................................................................................................. 4
3 215212 Bearing Strip................................................................................................................ 2
4 131716 Shim (0.020 in.) ........................................................................................................... 4
5 104506 O-Ring ......................................................................................................................... 4
6 1353192 Load Roller ("B") (0,76 mm)......................................................................................... AR
6 1353193 Load Roller ("C") (1,52 mm) ........................................................................................ AR
6 1395169 Load Roller ("A") (Optional) ......................................................................................... 2
6 1395173 Load Roller ("A") (Standard) ........................................................................................ 2
6 1395175 Load Roller ("A") (Optional) ......................................................................................... 2
7 58901 Snap Ring.................................................................................................................... 4
8 129387 Shim (0.020 in.) ........................................................................................................... AR
9 304526 Snap Ring.................................................................................................................... 2
10 b 1345183 Chain Sheave .............................................................................................................. 2
10 c 1379685 Chain Sheave Assembly.............................................................................................. 2
11 b 1345181 Sheave .................................................................................................................... 1
11 c 1378698 Sheave .................................................................................................................... 1
12 b 231020 Bearing .................................................................................................................... 1
12 c 1378699 Bearing .................................................................................................................... 1
13 b 37752 Snap Ring................................................................................................................ 2
13 c 37752 Snap Ring................................................................................................................ 1
14 d 1379707 Spacer ......................................................................................................................... 4
FOOTNOTES:
a Refer to Table
b ⇒ S/N PENDING PER ECN 59458
c S/N PENDING PER ECN 59458 ⇒
d S/N PENDING PER ECN 59458⇔S/N PENDING PER ECN 70489
INNER MAST
THREE STAGE FULL FREE-LIFT
1 a .. . . . Inner Mast.................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 58901 Snap Ring.................................................................................................................... 2
4 129387 Shim (0.020 in.) ........................................................................................................... AR
5 1353192 Load Roller ("B") (0,76 mm)......................................................................................... AR
5 1353193 Load Roller ("C") (1,52 mm) ........................................................................................ AR
5 1395169 Load Roller ("A") (Optional) ......................................................................................... 2
5 1395173 Load Roller ("A") (Standard) ........................................................................................ 2
5 1395175 Load Roller ("A") (Optional) ......................................................................................... 2
FOOTNOTES:
a Refer to Table
MAIN LIFT
THREE STAGE FULL FREE-LIFT
(⇒S/N A554L-18550)
1 a .. . . . Chain ........................................................................................................................... 2
2 .. . . . Main Lift Cylinder (LH) (☞ Figure 10-7) ..................................................................... 1
2 .. . . . Main Lift Cylinder (RH) (☞ Figure 10-8) .................................................................... 1
4 292531 Capscrew..................................................................................................................... 2
5 296422 Washer ........................................................................................................................ 4
6 323090 Spacer ......................................................................................................................... 2
7 300937 Nut ............................................................................................................................... 2
8 131358 Snap Ring.................................................................................................................... 2
9 1333382 Washer ........................................................................................................................ 2
10 1354915 Washer ........................................................................................................................ AR
10 1354916 Washer ........................................................................................................................ AR
10 1354917 Washer ........................................................................................................................ AR
11 177589 Clamp .......................................................................................................................... 1
12 136704 Capscrew..................................................................................................................... 2
13 313828 Nut ............................................................................................................................... 4
14 320157 Washer ........................................................................................................................ 2
15 1363250 Plate ............................................................................................................................ 1
16 287851 Capscrew..................................................................................................................... 2
17 1363251 Clamp .......................................................................................................................... 1
18 1353399 Tube ............................................................................................................................. 1
19 323061 Control Valve ............................................................................................................... 1
20 1333392 Housing ....................................................................................................................... 1
21 16542 Fitting........................................................................................................................... 1
21 16485 O-Ring ..................................................................................................................... 1
22 16543 Fitting........................................................................................................................... 1
22 16486 O-Ring ..................................................................................................................... 1
23 1362391 Hose ............................................................................................................................ 1
24 1362392 Hose ............................................................................................................................ 1
25 17063 Fitting........................................................................................................................... 1
26 120938 Spring .......................................................................................................................... 2
27 323160 Washer ........................................................................................................................ 2
28 189595 Fitting........................................................................................................................... 2
28 16485 O-Ring ..................................................................................................................... 1
29 320313 Chain Anchor ............................................................................................................... 2
30 323161 Pin ............................................................................................................................... 4
31 15200 Cotter Pin..................................................................................................................... 4
32 1365140 Chain Anchor ............................................................................................................... 2
33 15223 Cotter Pin..................................................................................................................... 2
34 161003 Nut ............................................................................................................................... 4
35 297649 Ring ............................................................................................................................. 4
36 16882 Fitting........................................................................................................................... 1
MAIN LIFT
THREE STAGE FULL FREE-LIFT
(⇒S/N A554L-18550)
FOOTNOTES:
a Refer to Table
10-11
UNIT CODE D001
NORTH AMERICA 03/2002
MAIN LIFT
THREE STAGE FULL FREE-LIFT
(S/N A554L-1856⇒)
1 a .. . . . Chain ........................................................................................................................... 2
2 .. . . . Main Lift Cylinder (LH) (☞ Figure 10-7) ..................................................................... 1
3 .. . . . Main Lift Cylinder (RH) (☞ Figure 10-8) .................................................................... 1
4 292531 Capscrew..................................................................................................................... 2
5 296422 Washer ........................................................................................................................ 4
6 323090 Spacer ......................................................................................................................... 2
7 300937 Nut ............................................................................................................................... 2
8 131358 Snap Ring.................................................................................................................... 3
9 1333382 Washer ........................................................................................................................ 2
10 1354915 Washer ........................................................................................................................ AR
10 1354916 Washer ........................................................................................................................ AR
10 1354917 Washer ........................................................................................................................ AR
11 313828 Nut ............................................................................................................................... 4
12 136681 Capscrew..................................................................................................................... 4
13 17051 Fitting........................................................................................................................... 1
14 1363250 Plate ............................................................................................................................ 1
15 1363251 Clamp .......................................................................................................................... 1
16 16560 Fitting........................................................................................................................... 2
16 16485 O-Ring ..................................................................................................................... 2
17 323061 Control Valve ............................................................................................................... 1
18 1333392 Housing ....................................................................................................................... 1
19 189595 Fitting........................................................................................................................... 1
20 15223 Cotter Pin..................................................................................................................... 2
21 161003 Nut ............................................................................................................................... 4
22 297649 Ring ............................................................................................................................. 4
23 16543 Fitting........................................................................................................................... 1
23 16486 O-Ring ..................................................................................................................... 1
24 323161 Pin ............................................................................................................................... 4
25 15200 Cotter Pin..................................................................................................................... 4
26 c 1369357 Chain Anchor ............................................................................................................... 2
26 b 320313 Chain Anchor ............................................................................................................... 2
27 1365140 Chain Anchor ............................................................................................................... 2
28 120938 Spring .......................................................................................................................... 1
29 323160 Washer ........................................................................................................................ 1
30 1376324 Tube ............................................................................................................................. 1
31 1376100 Hose ............................................................................................................................ 1
32 16882 Fitting........................................................................................................................... 1
33 292509 Capscrew..................................................................................................................... 2
34 1345403 Hose ............................................................................................................................ 1
MAIN LIFT
THREE STAGE FULL FREE-LIFT
(S/N A554L-1856⇒)
FOOTNOTES:
a Refer to Table
b ⇒ S/N A554L-1918
c S/N A554L-1919 ⇒
10-15
UNIT CODE D001
NORTH AMERICA 03/2002
FREE-LIFT
THREE STAGE FULL FREE-LIFT
1 a .. . . . Chain ........................................................................................................................... 2
2 a .. . . . Hose ............................................................................................................................ 1
3 161003 Nut ............................................................................................................................... 2
4 297649 Ring ............................................................................................................................. 2
5 323161 Pin ............................................................................................................................... 2
6 15200 Cotter Pin..................................................................................................................... 2
7 c 1369357 Chain Anchor ............................................................................................................... 2
7 b 320313 Chain Anchor ............................................................................................................... 2
8 1395285 Guard........................................................................................................................... 2
9 g 132680 Capscrew..................................................................................................................... 2
9 f 292526 Capscrew..................................................................................................................... 2
10 292683 Lockwasher.................................................................................................................. 3
11 1353547 Bracket......................................................................................................................... 1
12 302461 Pin ............................................................................................................................... 2
13 1344323 Bracket......................................................................................................................... 1
14 292528 Capscrew..................................................................................................................... 4
15 g 320161 Washer ........................................................................................................................ 2
15 f 320161 Washer ........................................................................................................................ 6
16 300937 Nut ............................................................................................................................... 4
17 1379496 Valve ............................................................................................................................ 1
18 d 1337905 Crosshead ................................................................................................................... 1
18 e 1378690 Crosshead ................................................................................................................... 1
19 292533 Capscrew..................................................................................................................... 1
20 1360534 Stubshaft ..................................................................................................................... 1
21 1343989 Sheave......................................................................................................................... 1
21 1354901 Bushing ................................................................................................................... 1
22 d 1354912 Chain Sheave .............................................................................................................. 2
22 e 1379682 Chain Sheave Assembly.............................................................................................. 2
23 e 37752 Snap Ring................................................................................................................ 1
23 d 37752 Snap Ring................................................................................................................ 2
24 e 1378699 Bearing .................................................................................................................... 1
24 d 231020 Bearing .................................................................................................................... 1
25 d 1354911 Sheave .................................................................................................................... 1
25 e 1378692 Sheave .................................................................................................................... 1
26 g 296422 Washer ........................................................................................................................ 4
27 304526 Snap Ring.................................................................................................................... 2
28 131358 Snap Ring.................................................................................................................... 1
29 .. . . . Free-Lift Cylinder (☞ Figure 10-9) ............................................................................. 1
FREE-LIFT
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
b ⇒ S/N A554L-1918
c S/N A554L-1919 ⇒
d ⇒ S/N A554L-3124
e S/N A554L-3125 ⇒
f ⇒ S/N A554L-4879
g S/N A554L-4880 ⇒
10-19
UNIT CODE D001
NORTH AMERICA 03/2002
a .. . . . Lift Cylinder.................................................................................................................. 1
1 a .. . . . Shell ........................................................................................................................ 1
2 a .. . . . Rod.......................................................................................................................... 1
3 1371653 Gland....................................................................................................................... 1
4 a .. . . . Spacer ..................................................................................................................... 1
5 257913 Check Valve............................................................................................................. 1
6 297531 Washer .................................................................................................................... 1
7 187388 Snap Ring................................................................................................................ 1
8 39348 O-Ring ..................................................................................................................... 1
9 1319668 Wiper Ring............................................................................................................... 1
10 1356749 Rod Seal.................................................................................................................. 1
11 55407 O-Ring ..................................................................................................................... 1
12 330692 Seal ......................................................................................................................... 1
13 322824 Back-Up Ring .......................................................................................................... 2
14 1362871 Wear Ring ............................................................................................................... 1
15 1362875 Piston Ring .............................................................................................................. 1
16 322902 Wear Ring ............................................................................................................... 1
17 186061 Packing Lubricant ........................................................................................................ AR
FOOTNOTES:
a Refer to Table
a .. . . . Lift Cylinder.................................................................................................................. 1
1 a .. . . . Shell ........................................................................................................................ 1
2 a .. . . . Rod.......................................................................................................................... 1
3 1371653 Gland....................................................................................................................... 1
4 a .. . . . Spacer ..................................................................................................................... 1
4 257913 Check Valve............................................................................................................. 1
6 297531 Washer .................................................................................................................... 1
7 187388 Snap Ring................................................................................................................ 1
8 39348 O-Ring ..................................................................................................................... 1
9 1319668 Wiper Ring............................................................................................................... 1
10 1356749 Rod Seal.................................................................................................................. 1
11 55407 O-Ring ..................................................................................................................... 1
12 330692 Seal ......................................................................................................................... 1
13 322824 Back-Up Ring .......................................................................................................... 2
14 1362871 Wear Ring ............................................................................................................... 1
15 1362875 Piston Ring .............................................................................................................. 1
16 322902 Wear Ring ............................................................................................................... 1
17 186061 Packing Lubricant ........................................................................................................ AR
FOOTNOTES:
a Refer to Table
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
a .. . . . Lift Cylinder.................................................................................................................. 1
1 a .. . . . Shell ........................................................................................................................ 1
2 a .. . . . Rod.......................................................................................................................... 1
3 2013099 Wiper ....................................................................................................................... 1
4 1358970 Seal ......................................................................................................................... 1
5 1362880 Gland....................................................................................................................... 1
6 615135 Back-Up Ring .......................................................................................................... 1
7 55146 O-Ring ..................................................................................................................... 1
8 638250 Back-Up Ring .......................................................................................................... 1
9 201829 Wiper Ring............................................................................................................... 1
10 1362881 Wear Ring ............................................................................................................... 1
11 257913 Check Valve............................................................................................................. 1
12 39348 O-Ring ..................................................................................................................... 1
13 297531 Washer .................................................................................................................... 1
14 187388 Snap Ring................................................................................................................ 1
15 1361302 Screw ...................................................................................................................... 1
16 190887 Seal ......................................................................................................................... 1
17 186061 Packing Lubricant ........................................................................................................ AR
1360141 Seal Kit (Includes Items 3-4, 6-10, 12, 16) .................................................................. 1
FOOTNOTES:
a Refer to Table
CARRIAGE
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 72449
b S/N PENDING PER ECN 72449 ⇒
10-29
UNIT CODE D001
NORTH AMERICA 03/2002
MAST INSTALLATION
THREE STAGE FULL FREE-LIFT
HEADER HOSE
THREE FUNCTION
THREE STAGE FULL FREE-LIFT
1 a .. . . . Hose ............................................................................................................................ 2
2 137852 Strap Clamp................................................................................................................. 2
3 d 1369323 Bracket......................................................................................................................... 1
3 e 1381771 Bracket......................................................................................................................... 1
4 136704 Capscrew..................................................................................................................... 2
5 136749 Capscrew..................................................................................................................... 8
6 313828 Nut ............................................................................................................................... 10
7 1345199 Hose Guide.................................................................................................................. 2
8 1345204 Snap Ring.................................................................................................................... 2
9 1369333 Clamp .......................................................................................................................... 1
10 1381642 Stubshaft ..................................................................................................................... 1
11 1494017 Sheave......................................................................................................................... 1
12 1381598 Bracket (RH) ................................................................................................................ 1
13 1345190 Washer ........................................................................................................................ 1
14 292533 Capscrew..................................................................................................................... 1
15 320161 Washer ........................................................................................................................ 1
16 300937 Nut ............................................................................................................................... 1
17 1360549 Spacer ......................................................................................................................... 1
18 293795 Capscrew..................................................................................................................... 4
19 f 239503 Nut ............................................................................................................................... 3
20 1363255 Bracket (RH) ................................................................................................................ 1
21 1360386 Clamp .......................................................................................................................... 2
22 1353464 Plate ............................................................................................................................ 1
23 1348247 Hose Guide.................................................................................................................. 1
24 292521 Capscrew..................................................................................................................... 1
25 320160 Washer ........................................................................................................................ 1
26 316826 Nut ............................................................................................................................... 1
27 1353530 Clamp .......................................................................................................................... 4
28 1360508 Clamp .......................................................................................................................... 2
29 1375574 Strap ............................................................................................................................ 2
30 17222 Fitting........................................................................................................................... 1
30 16483 O-Ring ..................................................................................................................... 1
31 f 1377371 Hose ............................................................................................................................ 1
31 g 1377371 Hose ............................................................................................................................ 2
32 f 1377372 Hose ............................................................................................................................ 1
33 16558 Fitting........................................................................................................................... 1
33 16483 O-Ring ..................................................................................................................... 1
34 f 2022830 Clamp .......................................................................................................................... 1
35 f 292681 Lockwasher.................................................................................................................. 1
36 i 1395291 Bracket (RH) ................................................................................................................ 1
HEADER HOSE
THREE FUNCTION
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
b ⇒ S/N A554L-4879
c S/N A554L-4880 ⇒
d ⇒ S/N PENDING PER ECN 70207
e S/N PENDING PER ECN 70207 ⇒
f ⇒ S/N PENDING PER ECN 72115-02
g S/N PENDING PER ECN 72115-02 ⇒
h ⇒ S/N PENDING PER ECN 73052-01
i S/N PENDING PER ECN 73052-01 ⇒
10-35
UNIT CODE D001
NORTH AMERICA 03/2002
HEADER HOSE
FOUR FUNCTION
THREE STAGE FULL FREE-LIFT
1 a .. . . . Hose ............................................................................................................................ 4
2 1375574 Strap ............................................................................................................................ 4
3 c 1369323 Bracket......................................................................................................................... 1
3 d 1381771 Bracket......................................................................................................................... 1
4 136704 Capscrew..................................................................................................................... 4
5 136749 Capscrew..................................................................................................................... 10
6 313828 Nut ............................................................................................................................... 14
7 1345199 Hose Guide.................................................................................................................. 4
8 1345204 Snap Ring.................................................................................................................... 4
9 1369333 Clamp .......................................................................................................................... 2
10 1381641 Stubshaft ..................................................................................................................... 2
11 1381595 Sheave......................................................................................................................... 2
12 1381598 Bracket (RH) ................................................................................................................ 1
13 1345190 Washer ........................................................................................................................ 2
14 292533 Capscrew..................................................................................................................... 2
15 320161 Washer ........................................................................................................................ 2
16 300937 Nut ............................................................................................................................... 2
17 1360549 Spacer ......................................................................................................................... 2
18 293795 Capscrew..................................................................................................................... 8
19 292681 Lockwasher.................................................................................................................. 1
20 239503 Nut ............................................................................................................................... 3
21 1360386 Clamp .......................................................................................................................... 4
22 1353464 Plate ............................................................................................................................ 1
23 1348246 Hose Guide (RH) ......................................................................................................... 1
24 292521 Capscrew..................................................................................................................... 2
25 320160 Washer ........................................................................................................................ 2
26 316826 Nut ............................................................................................................................... 2
27 1353530 Clamp .......................................................................................................................... 8
28 1360508 Clamp .......................................................................................................................... 4
29 1363255 Bracket (RH) ................................................................................................................ 1
30 1363256 Bracket (LH)................................................................................................................. 1
31 1381599 Bracket (LH)................................................................................................................. 1
32 1348247 Hose Guide (LH).......................................................................................................... 1
33 17222 Fitting........................................................................................................................... 2
33 16483 O-Ring ..................................................................................................................... 3
34 1377371 Hose ............................................................................................................................ 1
35 1368661 Hose ............................................................................................................................ 1
36 137852 Strap Clamp................................................................................................................. 4
37 e 239503 Nut ............................................................................................................................... 1
38 e 292681 Lockwasher.................................................................................................................. 1
HEADER HOSE
FOUR FUNCTION
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
b S/N A554L-4880 ⇒
c ⇒ S/N PENDING PER ECN 70207
d S/N PENDING PER ECN 70207 ⇒
e ⇒ S/N PENDING PER ECN 72115-02
f S/N PENDING PER ECN 72115-02 ⇒
g S/N PENDING PER ECN 73052-0 ⇒
h ⇒ S/N PENDING PER ECN 73052-01
i S/N PENDING PER ECN 73052-01 ⇒
10-39
UNIT CODE D001
NORTH AMERICA 03/2002
FORK
THREE STAGE FULL FREE-LIFT
KEY:
A: Full Bottom Taper (40 mm x 100 mm)
B: Standard Taper (40 mm x 100 mm)
C: Standard Taper (40 mm x 80 mm)
QTY
ITEM PART NO. DESCRIPTION A B C
NOTE:
Other Fork Dimensions Available on Request, Contact Your Hyster Lift Truck Dealer.
10-42
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 11
MAST-TWO STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-20
FORK
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-34
FREE-LIFT
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-10
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-18
HEADER HOSE
FOUR FUNCTION
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-30
THREE FUNCTION
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-26
INNER MAST
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-4
LOAD BACKREST EXTENSION
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-22
MAIN LIFT
TWO STAGE FULL FREE-LIFT
⇒S/N A558L-1559 ...................................................................................................................................... 11-6
S/N A558L-1560⇒ ...................................................................................................................................... 11-8
MAIN LIFT CYLINDER
LEFT HAND
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-14
RIGHT HAND
TWO STAGE FULL FREE-LIFT ................................................................................................................ 11-16
MAST INSTALLATION
TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-24
OUTER MAST
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-2
OUTER MAST
TWO STAGE FULL FREE-LIFT
1 a .. . . . Outer Mast................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 215212 Bearing Strip................................................................................................................ 2
4 131716 Shim (0.020 in.) ........................................................................................................... 4
5 104506 O-Ring ......................................................................................................................... 4
6 1353192 Load Roller ("B") (0,76 mm)......................................................................................... AR
6 1353193 Load Roller ("C") (1,52 mm) ........................................................................................ AR
6 1395169 Load Roller ("A") (Optional) ......................................................................................... 2
6 1395173 Load Roller ("A") (Standard) ........................................................................................ 2
6 1395175 Load Roller ("A") (Optional) ......................................................................................... 2
7 58901 Snap Ring.................................................................................................................... 2
8 129387 Shim (0.020 in.) ........................................................................................................... AR
FOOTNOTES:
a Refer to Table
INNER MAST
TWO STAGE FULL FREE-LIFT
1 a .. . . . Inner Mast.................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 1353192 Load Roller ("B") (0,76 mm)......................................................................................... AR
3 1353193 Load Roller ("C") (1,52 mm) ........................................................................................ AR
3 1395169 Load Roller ("A") (Optional) ......................................................................................... 2
3 1395173 Load Roller ("A") (Standard) ........................................................................................ 2
3 1395175 Load Roller ("A") (Optional) ......................................................................................... 2
4 58901 Snap Ring.................................................................................................................... 2
5 129387 Shim (0.020 in.) ........................................................................................................... AR
FOOTNOTES:
a Refer to Table
MAIN LIFT
TWO STAGE FULL FREE-LIFT
(⇒S/N A558L-1559)
MAIN LIFT
TWO STAGE FULL FREE-LIFT
(S/N A558L-1560⇒)
FREE-LIFT
TWO STAGE FULL FREE-LIFT
1 a .. . . . Chain ........................................................................................................................... 2
2 a .. . . . Hose ............................................................................................................................ 1
3 161003 Nut ............................................................................................................................... 2
4 297649 Ring ............................................................................................................................. 2
5 323161 Pin ............................................................................................................................... 2
6 15200 Cotter Pin..................................................................................................................... 2
7 c 1369357 Chain Anchor ............................................................................................................... 2
7 b 320313 Chain Anchor ............................................................................................................... 2
8 1395285 Guard........................................................................................................................... 2
9 e 132680 Capscrew..................................................................................................................... 2
9 d 292526 Capscrew..................................................................................................................... 2
10 292683 Lockwasher.................................................................................................................. 2
11 1353546 Bracket......................................................................................................................... 1
12 302461 Pin ............................................................................................................................... 2
13 1344323 Bracket......................................................................................................................... 1
14 287837 Capscrew..................................................................................................................... 4
15 e 320161 Washer ........................................................................................................................ 2
15 d 320161 Washer ........................................................................................................................ 6
16 300937 Nut ............................................................................................................................... 4
17 1379496 Valve ............................................................................................................................ 1
17 16485 O-Ring ..................................................................................................................... 1
18 b 1337905 Crosshead ................................................................................................................... 1
18 c 1378690 Crosshead ................................................................................................................... 1
19 320158 Washer ........................................................................................................................ 2
20 292681 Lockwasher.................................................................................................................. 2
21 132861 Capscrew..................................................................................................................... 2
22 178119 Clamp .......................................................................................................................... 1
23 239503 Nut ............................................................................................................................... 2
24 1380035 Fitting........................................................................................................................... 1
25 16882 Fitting........................................................................................................................... 1
26 304526 Snap Ring.................................................................................................................... 2
27 b 1354912 Chain Sheave .............................................................................................................. 2
27 c 1379682 Chain Sheave Assembly.............................................................................................. 2
28 c 37752 Snap Ring................................................................................................................ 1
28 b 37752 Snap Ring................................................................................................................ 2
29 c 1378699 Bearing .................................................................................................................... 1
29 b 231020 Bearing .................................................................................................................... 1
30 b 1354911 Sheave .................................................................................................................... 1
30 c 1378692 Sheave .................................................................................................................... 1
31 .. . . . Free-Lift Cylinder (☞ Figure 11-8) ............................................................................. 1
32 131358 Snap Ring.................................................................................................................... 1
FREE-LIFT
TWO STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
b ⇒ S/N A558L-1808
c S/N A558L-1809 ⇒
d ⇒ S/N A558L-2646
e S/N A558L-2647 ⇒
11-13
UNIT CODE D001
NORTH AMERICA 03/2002
a .. . . . Lift Cylinder.................................................................................................................. 1
1 a .. . . . Shell ........................................................................................................................ 1
2 a .. . . . Rod.......................................................................................................................... 1
3 1310369 Wiper Ring............................................................................................................... 1
4 1371654 Seal ......................................................................................................................... 1
5 1365689 Gland....................................................................................................................... 1
6 132834 Back-Up Ring .......................................................................................................... 1
7 55407 O-Ring ..................................................................................................................... 1
8 1374802 Wear Ring ............................................................................................................... 1
9 1362875 Piston Ring .............................................................................................................. 1
10 295649 Capscrew ................................................................................................................ 1
11 190887 Seal ......................................................................................................................... 1
12 186061 Packing Lubricant ........................................................................................................ AR
FOOTNOTES:
a Refer to Table
a .. . . . Lift Cylinder.................................................................................................................. 1
1 a .. . . . Shell ........................................................................................................................ 1
2 a .. . . . Rod.......................................................................................................................... 1
3 1310369 Wiper Ring............................................................................................................... 1
4 1371654 Seal ......................................................................................................................... 1
5 1365689 Gland....................................................................................................................... 1
6 132834 Back-Up Ring .......................................................................................................... 1
7 55407 O-Ring ..................................................................................................................... 1
8 1362871 Wear Ring ............................................................................................................... 1
9 190887 Seal ......................................................................................................................... 1
10 295649 Capscrew ................................................................................................................ 1
11 186061 Packing Lubricant ........................................................................................................ AR
FOOTNOTES:
a Refer to Table
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT
a .. . . . Lift Cylinder.................................................................................................................. 1
1 a .. . . . Shell ........................................................................................................................ 1
2 a .. . . . Rod.......................................................................................................................... 1
3 2013099 Wiper ....................................................................................................................... 1
4 1358970 Seal ......................................................................................................................... 1
5 1362880 Gland....................................................................................................................... 1
6 615135 Back-Up Ring .......................................................................................................... 1
7 55146 O-Ring ..................................................................................................................... 1
8 638250 Back-Up Ring .......................................................................................................... 1
9 201829 Wiper Ring............................................................................................................... 1
10 1362881 Wear Ring ............................................................................................................... 1
11 257913 Check Valve............................................................................................................. 1
12 39348 O-Ring ..................................................................................................................... 1
13 297531 Washer .................................................................................................................... 1
14 187388 Snap Ring................................................................................................................ 1
15 1361302 Screw ...................................................................................................................... 1
16 190887 Seal ......................................................................................................................... 1
17 186061 Packing Lubricant ........................................................................................................ AR
1360141 Seal Kit (Includes Items 3-4, 6-10, 12, 16) .................................................................. 1
FOOTNOTES:
a Refer to Table
CARRIAGE
TWO STAGE FULL FREE-LIFT
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 72449
b S/N PENDING PER ECN 72449 ⇒
11-23
UNIT CODE D001
NORTH AMERICA 03/2002
MAST INSTALLATION
TWO STAGE FULL FREE-LIFT
HEADER HOSE
THREE FUNCTION
TWO STAGE FULL FREE-LIFT
1 a .. . . . Channel ....................................................................................................................... 1
2 a .. . . . Channel ....................................................................................................................... 1
3 a .. . . . Hose ............................................................................................................................ 2
4 1375574 Strap ............................................................................................................................ 2
5 1360386 Clamp .......................................................................................................................... 1
6 1360507 Clamp .......................................................................................................................... 2
7 1360508 Clamp .......................................................................................................................... 4
8 1365061 Clip .............................................................................................................................. 1
9 14692 Fitting........................................................................................................................... 2
10 1360386 Clamp .......................................................................................................................... 2
11 1345423 Clamp .......................................................................................................................... 2
12 1354918 Bracket......................................................................................................................... 1
13 293796 Capscrew..................................................................................................................... 6
14 d 1369323 Bracket......................................................................................................................... 1
14 e 1381771 Bracket......................................................................................................................... 1
15 1369333 Clamp .......................................................................................................................... 1
16 136749 Capscrew..................................................................................................................... 6
17 313828 Nut ............................................................................................................................... 6
18 1345199 Hose Guide.................................................................................................................. 2
19 1345204 Snap Ring.................................................................................................................... 2
20 2004005 Strap Clamp................................................................................................................. 1
21 a .. . . . Tube ............................................................................................................................. 1
22 a .. . . . Tube ............................................................................................................................. 1
23 1353530 Clamp .......................................................................................................................... 5
24 1360507 Clamp .......................................................................................................................... 3
25 17222 Fitting........................................................................................................................... 1
25 16483 O-Ring ..................................................................................................................... 1
26 f 1377371 Hose ............................................................................................................................ 1
26 g 1377371 Hose ............................................................................................................................ 2
27 g 1377372 Hose ............................................................................................................................ 1
28 137852 Strap Clamp................................................................................................................. 2
29 16558 Fitting........................................................................................................................... 1
29 16483 O-Ring ..................................................................................................................... 1
30 f 2022830 Clamp .......................................................................................................................... 1
31 f 239503 Nut ............................................................................................................................... 3
HEADER HOSE
THREE FUNCTION
TWO STAGE FULL FREE-LIFT
32 f 292681 Lockwasher.................................................................................................................. 1
33 b 1395291 Bracket (RH) ................................................................................................................ 1
34 b 1396406 Stubshaft ..................................................................................................................... 1
35 b 1396407 Spacer ......................................................................................................................... 1
35 c 320171 Washer ........................................................................................................................ 1
36 b 282533 Capscrew..................................................................................................................... 1
37 b 300937 Nut ............................................................................................................................... 1
38 b 1345190 Washer ........................................................................................................................ 1
39 b 1494017 Sheave......................................................................................................................... 2
FOOTNOTES:
a Refer to Table
b S/N PENDING PER ECN 73052-01⇔S/N A555L-14195
c S/N A555L-14196 ⇒
d ⇒ S/N PENDING PER ECN 70207
e S/N PENDING PER ECN 70207 ⇒
f ⇒ S/N PENDING PER ECN 72115-02
g S/N PENDING PER ECN 72115-02 ⇒
h ⇒ S/N PENDING PER ECN 73052-01
11-29
UNIT CODE D001
NORTH AMERICA 03/2002
HEADER HOSE
FOUR FUNCTION
TWO STAGE FULL FREE-LIFT
1 a .. . . . Channel ....................................................................................................................... 1
2 a .. . . . Channel ....................................................................................................................... 1
3 a .. . . . Hose ............................................................................................................................ 4
4 1375574 Strap ............................................................................................................................ 4
5 1360386 Clamp .......................................................................................................................... 2
6 1360507 Clamp .......................................................................................................................... 5
7 1360508 Clamp .......................................................................................................................... 4
8 1365061 Clip .............................................................................................................................. 1
9 14692 Fitting........................................................................................................................... 2
10 1360386 Clamp .......................................................................................................................... 4
11 1345423 Clamp .......................................................................................................................... 2
12 1354918 Bracket......................................................................................................................... 1
13 296001 Capscrew..................................................................................................................... 4
14 c 1369323 Bracket......................................................................................................................... 1
14 d 1381771 Bracket......................................................................................................................... 1
15 1369333 Clamp .......................................................................................................................... 2
16 136749 Capscrew..................................................................................................................... 8
17 313828 Nut ............................................................................................................................... 8
18 1345199 Hose Guide.................................................................................................................. 4
19 1345204 Snap Ring.................................................................................................................... 4
20 2004005 Strap Clamp................................................................................................................. 2
21 293795 Capscrew..................................................................................................................... 2
22 a .. . . . Tube ............................................................................................................................. 1
23 a .. . . . Tube ............................................................................................................................. 1
24 a .. . . . Hose ............................................................................................................................ 2
25 17222 Fitting........................................................................................................................... 1
25 16483 O-Ring ..................................................................................................................... 1
26 e 1377371 Hose ............................................................................................................................ 1
26 f 1377371 Hose ............................................................................................................................ 2
27 e 1377372 Hose ............................................................................................................................ 1
28 137852 Strap Clamp................................................................................................................. 4
29 e 239503 Nut ............................................................................................................................... 1
30 e 292681 Lockwasher.................................................................................................................. 1
31 e 320157 Washer ........................................................................................................................ 1
HEADER HOSE
FOUR FUNCTION
TWO STAGE FULL FREE-LIFT
32 292681 Lockwasher.................................................................................................................. 1
33 e 292508 Capscrew..................................................................................................................... 1
34 f 1377372 Hose ............................................................................................................................ 1
34 e 1377373 Hose ............................................................................................................................ 1
35 f 1377372 Hose ............................................................................................................................ 1
35 e 1377374 Hose ............................................................................................................................ 1
36 e 101625 Clamp .......................................................................................................................... 2
37 16558 Fitting ........................................................................................................................... 1
37 16483 O-Ring ..................................................................................................................... 1
38 2022830 Clamp .......................................................................................................................... 1
39 239503 Nut ............................................................................................................................... 3
40 1353530 Clamp .......................................................................................................................... 1
41 b 1395291 Bracket (RH) ................................................................................................................ 1
42 b 1395292 Bracket (LH)................................................................................................................. 1
43 b 1396406 Stubshaft ..................................................................................................................... 2
44 b 1396407 Spacer ......................................................................................................................... 2
44 320171 Washer ........................................................................................................................ 2
45 b 292533 Capscrew..................................................................................................................... 2
46 b 300937 Nut ............................................................................................................................... 2
47 b 1345190 Washer ........................................................................................................................ 2
48 b 1494017 Sheave......................................................................................................................... 2
FOOTNOTES:
a Refer to Table
b S/N PENDING PER ECN 73052-01⇔S/N A555L-14195
c ⇒ S/N PENDING PER ECN 70207
d S/N PENDING PER ECN 70207 ⇒
e ⇒ S/N PENDING PER ECN 72115-02
f S/N PENDING PER ECN 72115-02 ⇒
g ⇒ S/N PENDING PER ECN 73052-01
11-33
UNIT CODE D001
NORTH AMERICA 03/2002
FORK
TWO STAGE FULL FREE-LIFT
KEY:
A: Full Bottom Taper (40 mm x 100 mm)
B: Standard Taper (40 mm x 100 mm)
C: Standard Taper (40 mm x 80 mm)
QTY
ITEM PART NO. DESCRIPTION A B C
NOTE:
Other Fork Dimensions Available on Request, Contact Your Hyster Lift Truck Dealer.
11-36
UNIT CODE D001
03/2002 NORTH AMERICA
12 OPTIONS
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 12
OPTIONS
DESCRIPTION PAGE
SIDE-SHIFT CARRIAGE
FOOTNOTES:
a Two and Three Stage Full Free-Lift
b Two Stage Full Free-Lift
c ⇒ S/N B601B-11719
d S/N B601B-11720 ⇒
e ⇒ S/N PENDING PER ECN 70207
f S/N PENDING PER ECN 70207 ⇒
g ⇒ S/N PENDING PER ECN 73164
h S/N PENDING PER ECN 73164 ⇒
SIDE-SHIFT CYLINDER
FENDER
(⇒S/N D001H-3018)
KEY:
A: 930 mm Tread, Left Hand
B: 930 mm Tread, Right Hand
C: 1060 mm Tread, Left Hand
D: 1060 mm Tread, Right Hand
QTY
ITEM PART NO. DESCRIPTION A B C D
LIFTING EYE
KEY:
A: All Models 6.50-10 Pneumatic Shaped Solid
B: H25-35XM 6.50-10-10 Pneumatic
C: H40XM 6.50-10-12 Pneumatic
D: H40XM 6.50-10-12 Pneumatic (Optional)
QTY
ITEM PART NO. DESCRIPTION A B C D
FOOTNOTES:
a Intermediate Tread (930 mm [38 inch])
b Standard Tread (887 mm [35 inch])
c Wide Tread (1060 mm [44 inch])
KEY:
A: H25-35XM 6.50-10-10 Pneumatic
B: H40XM 6.50-10-12 Black
C: H40XM 6.50-10-12 Pneumatic
QTY
ITEM PART NO. DESCRIPTION A B C
1 2022924 Wheel ....................................................................................................... 1 1 1
2 2023321 Rim (Inner) ........................................................................................... 1 1 1
3 2023322 Rim (Outer)........................................................................................... 1 1 1
4 288638 Label (Warning).................................................................................... 2 2 2
5 2021575 Wheel Stud ............................................................................................... 6 6 6
6 292683 Lockwasher............................................................................................... 6 6 6
7 303110 Nut ............................................................................................................ 6 6 6
8 2021578 Tire ........................................................................................................... .. 1 ..
8 2023485 Tire ........................................................................................................... .. .. 1
8 306015 Tire ........................................................................................................... 1 .. ..
9 1370732 Tire and Flap ........................................................................................ .. 1 ..
9 2023487 Tire and Flap ........................................................................................ .. .. 1
9 306016 Tire and Flap ........................................................................................ 1 .. ..
10 2022789 Tube...................................................................................................... .. 1 ..
10 306198 Tube...................................................................................................... 1 .. 1
NOTE:
All items listed are for Standard Tread (887 mm [35 inch]) tires.
12-13
UNIT CODE D001
NORTH AMERICA 03/2002
KEY:
A: All Models 5.00-8 Pneumatic Shaped Solid
B: H25-35XM 5.00-8-8 Pneumatic
C: H40XM 5.00-8-10 Pneumatic
QTY
ITEM PART NO. DESCRIPTION A B C
KEY:
A: H25-35XM 5.00-8-8 Pneumatic
B: H40XM 5.00-8-10 Pneumatic
C: H40XM 5.00-8-10 (Optional)
QTY
ITEM PART NO. DESCRIPTION A B C
12-17
UNIT CODE D001
NORTH AMERICA 03/2002
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 76392
b S/N PENDING PER ECN 76392 ⇒
STROBE LIGHT
FOOTNOTES:
a High Mount
b Low Mount
c Optional, Europe
d Without Rear Lights
e ⇒ S/N D001H-3493
f S/N D001H-3494 ⇒
FIRE EXTINGUISHER
12-25
UNIT CODE D001
NORTH AMERICA 03/2002
BACKUP ALARM
KEY:
A: 90 dbA Alarm
B: 87, 97, 107, and 82-102 dbA Alarms
QTY
ITEM PART NO. DESCRIPTION A B
1 2023314 Bracket................................................................................................................. 1 1
2 292500 Capscrew............................................................................................................. .. 2
3 296417 Lockwasher.......................................................................................................... .. 2
4 302399 Nut ....................................................................................................................... .. 2
5 1361552 Wire Harness....................................................................................................... .. 1
6 1350733 Alarm (87 dBA) .................................................................................................... .. 1
6 1350735 Alarm (102 dBA) .................................................................................................. .. 1
6 1339947 Alarm (82-102 dBA)............................................................................................. .. 1
6 1350734 Alarm (97 dBA) .................................................................................................... .. 1
6 1350736 Alarm (107 dBA) .................................................................................................. .. 1
7 136681 Capscrew............................................................................................................. 1 ..
8 292681 Lockwasher.......................................................................................................... 1 ..
9 320157 Washer ................................................................................................................ 1 ..
10 239503 Nut ....................................................................................................................... 2 ..
11 1343892 Alarm (90 dBA) .................................................................................................... 1 ..
KEY:
A: Three Function Group
B: Four Function Group
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: Three Function Group
B: Four Function Group
QTY
ITEM PART NO. DESCRIPTION A B
12-32
UNIT CODE D001
03/2002 NORTH AMERICA
13 NUMERICAL INDEX
UNIT CODE D001
03/2002 NORTH AMERICA
SECTION 13
NUMERICAL INDEX
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
142 3-3 19 10-9 31 11-27 29 12-31 12
12445 3-29 19 10-13 25 11-31 25 16719 3-33 5
3-31 1 10-17 6 11-32 37 16751 3-13 27
3-33 1 10-27 11 16485 8-3 29 16849 3-31 21
12490 3-29 6 11-11 6 8-4 45 3-33 20
12838 4-9 35 11-21 11 8-7 34 16863 3-23 17
14189 6-5 28 15212 3-3 13 9-7 9 16865 3-5 18
14603 9-7 20 3-8 6 9-7 19 4-22 41
9-9 18 6-3 17 9-9 9 16882 9-7 30
11-7 20 15222 1-9 10 9-9 17 9-9 27
11-9 16 8-20 46 10-9 21 10-9 36
14604 5-7 44 8-24 46 10-9 28 10-13 32
14691 8-4 48 15223 2-22 14 10-13 16 11-7 24
8-7 37 2-23 14 11-7 19 11-9 17
14692 11-27 9 2-45 14 11-7 21 11-11 25
11-31 9 10-9 33 11-9 21 16923 8-4 52
15005 6-5 22 10-13 20 11-11 17 8-8 42
15152 3-5 6 15444 4-9 36 16486 9-7 20 16982 9-7 10
15155 6-3 25 15855 12-21 18 9-9 18 9-9 10
15175 1-3 23 15962 5-47 5 10-9 22 16987 8-7 24
1-9 27 15963 3-23 30 10-13 23 16997 8-8 46
1-11 21 16001 9-19 6 11-7 20 17051 9-9 14
1-13 2 9-19 22 11-9 16 10-13 13
1-15 36 10-31 6 16487 5-7 44 11-9 14
8-19 18 10-31 22 16540 8-4 66 17059 8-3 37
8-23 18 11-25 6 8-7 38 8-7 25
8-43 18 11-25 22 16542 9-7 9 17063 9-7 15
8-45 18 16041 12-3 12 10-9 21 10-9 25
15176 2-55 13 16186 4-3 40 11-7 21 11-7 16
2-57 10 16447 12-29 11 16543 10-9 22 17222 8-24 48
15177 1-7 5 12-31 11 10-13 23 8-45 41
1-9 23 16481 8-3 43 16556 8-3 43 9-21 26
2-22 10 8-3 44 8-3 44 9-23 28
2-23 10 8-7 32 8-7 32 10-33 30
2-45 10 12-3 14 16558 6-7 32 10-37 33
2-47 15 16483 8-3 32 8-3 32 11-27 25
2-49 12 8-3 34 8-7 21 11-31 25
2-51 13 8-4 66 8-24 49 17314 3-27 22
2-53 10 8-4 67 8-45 42 17627 8-3 36
2-55 20 8-7 21 9-21 20 17636 3-45 11
2-57 16 8-7 23 9-23 21 3-47 11
8-19 3 8-7 38 10-33 33 8-3 9
8-23 3 8-8 60 10-38 40 8-7 10
8-43 3 9-21 20 11-27 29 18419 4-22 39
8-45 3 9-21 26 11-32 37 18496 1-11 20
15200 3-3 25 9-23 21 16560 8-3 45 1-13 1
3-6 4 9-23 28 9-9 9 18497 4-7 7
3-7 4 10-33 30 10-13 16 4-11 13
3-8 10 10-33 33 11-9 21 18515 1-13 18
9-7 25 10-37 33 16567 6-7 31 6-3 26
9-9 23 10-38 40 16600 12-3 19 18727 1-11 19
9-15 11 11-27 25 16693 12-29 12 1-13 17
©2002 HYSTER COMPANY See Service Manual 13-1
for service procedures.
UNIT CODE D001
NORTH AMERICA 03/2002
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM