PARTS

MANUAL
W25ZC, W30ZC, W40ZC
(B454)

CUSTOMER EDITION

1524245 ©2003 Hyster Company

03/2003
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SECTIONS

1 FRAME/DRIVE UNIT

2 ELECTRICAL SYSTEM

3 STEER HANDLE/BRAKE SYSTEM

4 LOAD WHEEL

5 HYDRAULIC SYSTEM

6 MAST-TWO STAGE LIMITED FREE-LIFT

7 MAST-THREE STAGE FULL FREE-LIFT

8 CARRIAGE

9 OPTIONS

10 NUMERICAL INDEX

This Parts Manual is divided into 10 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the
pages to the corresponding tab.
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TABLE OF CONTENTS

DESCRIPTION PAGE

B
BATTERY DISCONNECT..................................................................................................................................... 1-6
BATTERY ROLLER .............................................................................................................................................. 9-2
BATTERY SPACER .............................................................................................................................................. 1-8

C
CARRIAGE
THREE STAGE FULL FREE-LIFT
W25ZC, W30ZC ............................................................................................................................................ 8-3
W40ZC .......................................................................................................................................................... 8-2
TWO STAGE LIMITED FREE-LIFT
W25ZC, W30ZC ............................................................................................................................................ 8-6
W40ZC .......................................................................................................................................................... 8-4
CHAINS, PINS AND ANCHORS
THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-4
CHAINS, PINS, AND ANCHORS
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 6-4
CONTROL PANEL ASSEMBLY............................................................................................................................ 2-2
COUNTERWEIGHT
2500 LB........................................................................................................................................................... 1-10
3000 AND 4000 LB ......................................................................................................................................... 1-12
COVERS .............................................................................................................................................................. 1-4

E
ELECTRIC BRAKE............................................................................................................................................... 3-2
ELECTRICAL ARRANGEMENT .......................................................................................................................... 2-4

F
FREE LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-6

H
HEADER HOSE
THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-8
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 6-6
HOSE TAKE UP
THREE STAGE
SINGLE FUNCTION...................................................................................................................................... 9-4
HYDRAULIC POWER UNIT ................................................................................................................................. 5-2
HYDRAULIC PUMP AND MOTOR ASSEMBLY ................................................................................................... 5-4

I
INNER AND OUTER MAST
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 6-2
INNER, INTERMEDIATE, AND OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-2

©2003 HYSTER COMPANY See Service Manual i

for service procedures.
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TABLE OF CONTENTS (Continued)

DESCRIPTION PAGE

L
LABELS AND DECALS ........................................................................................................................................ 1-2
LIFT
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 6-8
LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-12
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 6-10
LOAD BACKREST AND FORKS
HOOK TYPE CARRIAGE ................................................................................................................................. 9-8
LOAD WHEEL ...................................................................................................................................................... 4-2

M
MAIN FREE-LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-14
MASTER DRIVE UNIT ....................................................................................................................................... 1-18
MASTER DRIVE UNIT ASSEMBLY ................................................................................................................... 1-14

S
SIDE-SHIFT CARRIAGE.................................................................................................................................... 9-10
SIDE-SHIFT CYLINDER .................................................................................................................................... 9-12
STEER HANDLE ARM ASSEMBLY ..................................................................................................................... 3-4
STEER HANDLE ASSEMBLY .............................................................................................................................. 3-6

T
TILT CYLINDER
ROD ENDS AND PINS ..................................................................................................................................... 5-6
TRACTION MOTOR ............................................................................................................................................. 2-6

W
WIRE HARNESS................................................................................................................................................ 2-10
MAIN TRUCK.................................................................................................................................................... 2-8

Z
ZAPI-HANDSET KIT........................................................................................................................................... 9-15
ZAPI-LAPTOP/PC KIT (WINDOWS) .................................................................................................................. 9-14

ii See Service Manual ©2003 HYSTER COMPANY

for service procedures.
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ABBREVIATIONS QUICK REFERENCE SHEET

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

TERM DEFINITION TERM DEFINITION

Amp Amperes FRE Freezer Environment
AR As Required in. inches
BDI Battery Discharge Indicators LPG Liquefied Petroleum Gas
BWI Brush Wear Indicator MAP Manifold Absolute Pressure
CE Communicator End mm millimeters
CRE Corrosive Environment
MSTS Microprocessor Spark Timing System
D/B Date Break
NPT National Pipe Threads
dbA Decibel "A" Scale
O/S Oversize
DE Drive End
PTO Power Take Off
ECH Empty Container Handler
RPM Revolutions per Minute
ECH-3 Empty Container Handler - 3 High
S/N Serial Number
Stacking
TMM Truck Management Module
ECH-4 Empty Container Handler - 4 High
Stacking UL Type D Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High UL Type DS Diesel-Powered Safety Rating
Stacking UL Type E Battery-Powered Safety Rating
ECH-6 Empty Container Handler - 6 High UL Type EE Battery-Powered Safety Rating
Stacking UL Type ES Battery-Powered Safety Rating
ECH-7 Empty Container Handler - 7 High UL Type G Gasoline-Powered Safety Rating
Stacking
UL Type GS Gasoline-Powered Safety Rating
ECM Electronic Control Module
UL Type LP Gas-Powered Safety Rating
ECN Engineering Change Notice
UL Type LPS LP Gas-Powered Safety Rating
EEPROM Electrically Erasable Programmable
U/S Undersize
Read Only Memory
UL Underwriters Laboratory
EPROM Electrically Programmable Read Only
Memory V Volts

©2003 HYSTER COMPANY See Service Manual iii

for service procedures.
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HOW TO USE THE ILLUSTRATED PARTS MANUAL

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

iv See Service Manual ©2003 HYSTER COMPANY

for service procedures.
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HOW TO FIND THE DESIRED PART NUMBER

WHEN THE PART NUMBER AND THE NEXT previous page, BEARING CAP (Item 2) is a
HIGHER ASSEMBLY IS NOT KNOWN: subpart of the major assembly CASE.

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 10-1 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.

©2003 HYSTER COMPANY See Service Manual v

for service procedures.
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IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957 and 1980.
The letters "I", "O", and "Q" will not be used.
For pending serial numbers contact your local dealer for Hyster lift trucks.

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

vi See Service Manual ©2003 HYSTER COMPANY

for service procedures.
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PUBLICATIONS

Every new lift truck is provided with an OPERATING MANUAL. This manual has information that the operator
must know for inspection and operation of the lift truck.

SERVICE MAINTENANCE MANUALS, which provide service and overhaul procedures, and PARTS MANUALS
with complete replacement part identification, are available at a nominal fee from your Hyster dealer to assist
users in effectively maintaining Hyster lift trucks in a safe, useful condition. See the list below for information on
ordering specific publications for this model lift truck.

PUBLICATION HYSTER PART NUMBER

Operating Manual .................................................................................................................. 1506716

Service Manual (Complete) .................................................................................................. 1524247

Parts Manual .......................................................................................................................... 1524245

©2003 HYSTER COMPANY See Service Manual vii

for service procedures.
NOTES

viii
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1 FRAME/DRIVE UNIT

1 FRAME/DRIVE UNIT
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SECTION 1
FRAME/DRIVE UNIT

DESCRIPTION PAGE

BATTERY DISCONNECT..................................................................................................................................... 1-6

BATTERY SPACER .............................................................................................................................................. 1-8
COUNTERWEIGHT
2500 LB........................................................................................................................................................... 1-10
3000 AND 4000 LB ......................................................................................................................................... 1-12
COVERS .............................................................................................................................................................. 1-4
LABELS AND DECALS ........................................................................................................................................ 1-2
MASTER DRIVE UNIT ....................................................................................................................................... 1-18
MASTER DRIVE UNIT ASSEMBLY ................................................................................................................... 1-14

©2003 HYSTER COMPANY See Service Manual 1-1

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

LABELS AND DECALS (Figure 1-1)

1-2 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

LABELS AND DECALS

ITEM PART NO. DESCRIPTION QTY

1 2308468 Label (Fork Warning) ................................................................................................... 2

2 2034124 Label (Mast Warning) .................................................................................................. 2
3 2053653 Label (Warning and Instruction) .................................................................................. 1
4 1529042 Label (Hyster) .............................................................................................................. 2
5 1479130 Label (Dash) ................................................................................................................ 1
6 1506716 Operator Manual.......................................................................................................... 1
7 389692 Label (US Patents and Trademarks)............................................................................ 1
8 2044484 Label (Battery Discharge Notice) (Flooded Batteries) ................................................. 1
8 2050774 Label (Battery Discharge Notice) (Maintenance Free) ................................................ 1
9 1494689 Plate (UL Type E) ........................................................................................................ 1
10 389688 Cover ........................................................................................................................... 1
11 a .. . . . Nameplate ................................................................................................................... 1
12 2307400 Rivet............................................................................................................................. 4
13 1529043 Label (Hyster) .............................................................................................................. 2
14 2055918 Label (Manual Lowering) ............................................................................................. 1
15 b 2770775 Label (Snowflake) ........................................................................................................ 2
16 2054342 Label (Sideshift)........................................................................................................... 1
17 2054831 Label (Tilt).................................................................................................................... 1

FOOTNOTES:
a Contact your dealer.
b Only used on Cold Storage.

©2003 HYSTER COMPANY See Service Manual 1-3

for service procedures.
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NORTH AMERICA 03/2003

COVERS (Figure 1-2)

1-4 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
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03/2003 NORTH AMERICA

COVERS

ITEM PART NO. DESCRIPTION QTY

1 1468390 Front Cover .................................................................................................................. 1

2 2036141 Plate ............................................................................................................................ 1
3 2306899 Clip .............................................................................................................................. 1
4 2040664 Rivet............................................................................................................................. 4
5 335989 Base (Information Case).............................................................................................. 1
6 335991 Cover (Information Case) ............................................................................................ 1
7 227089 Screw........................................................................................................................... 2
8 1525540 Cover (2500 lb) ............................................................................................................ 1
8 1525541 Cover (3000 and 4000 lb) ............................................................................................ 1
9 1525537 Front Cover (2500 and 3000 lb)................................................................................... 1
9 1525539 Front Cover (4000 lb)................................................................................................... 1
10 2034380 Screw........................................................................................................................... 12
11 2034381 Washer ........................................................................................................................ 12
12 2034382 Spring Nut Clip ............................................................................................................ 12

©2003 HYSTER COMPANY See Service Manual 1-5

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

BATTERY DISCONNECT (Figure 1-3)

1-6 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

BATTERY DISCONNECT

ITEM PART NO. DESCRIPTION QTY

1 2053814 Battery Connector and Cable Assembly (Red)............................................................ 1

1 288835 Battery Connector (Red).............................................................................................. 1
1 2053813 Battery Connector and Cable Assembly (Gray)........................................................... 1
1 1195971 Battery Connector (Gray)............................................................................................. 1
2 2033589 Handle ......................................................................................................................... 1
3 220359 Screw........................................................................................................................... 4
4 15154 Lockwasher.................................................................................................................. 2
5 15054 Nut ............................................................................................................................... 2
6 264150 Nut ............................................................................................................................... 2

©2003 HYSTER COMPANY See Service Manual 1-7

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

BATTERY SPACER (Figure 1-4)

1-8 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

BATTERY SPACER

ITEM PART NO. DESCRIPTION QTY

1 2034556 Bracket......................................................................................................................... 2
2 15178 Washer ........................................................................................................................ 2
3 15158 Lockwasher.................................................................................................................. 2
4 221712 Nut ............................................................................................................................... 2
5 2306348 Spacer ......................................................................................................................... 2
6 16828 Capscrew..................................................................................................................... 2
7 15134 Washer ........................................................................................................................ 2
8 15156 Lockwasher.................................................................................................................. 2
9 15056 Nut ............................................................................................................................... 2

©2003 HYSTER COMPANY See Service Manual 1-9

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

COUNTERWEIGHT (Figure 1-5)

2500 LB

1-10 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

COUNTERWEIGHT
2500 LB

ITEM PART NO. DESCRIPTION QTY

1 .. . . . Counterweight ............................................................................................................. 1
2 18599 Capscrew..................................................................................................................... 1
3 15178 Washer ........................................................................................................................ 2
4 15158 Lockwasher.................................................................................................................. 1
5 15058 Nut ............................................................................................................................... 1

©2003 HYSTER COMPANY See Service Manual 1-11

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

COUNTERWEIGHT (Figure 1-6)

3000 AND 4000 LB

1-12 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

COUNTERWEIGHT
3000 AND 4000 LB

ITEM PART NO. DESCRIPTION QTY

1 .. . . . Counterweight ............................................................................................................. 1
2 17276 Capscrew..................................................................................................................... 1
3 15178 Washer ........................................................................................................................ 2
4 15158 Lockwasher.................................................................................................................. 1
5 15058 Nut ............................................................................................................................... 1

©2003 HYSTER COMPANY See Service Manual 1-13

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

MASTER DRIVE UNIT ASSEMBLY (Figure 1-7)

1-14 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

MASTER DRIVE UNIT ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

2045094 Drive Unit ..................................................................................................................... 1

1 1534179 Plug ......................................................................................................................... 1
2 1479432 Seal ......................................................................................................................... 1
3 1534286 Housing Support ..................................................................................................... 1
4 1534181 Centering Bush ....................................................................................................... 4
5 1534182 Bearing .................................................................................................................... 2
6 1534183 Gasket ..................................................................................................................... 1
7 1534186 Bolt .......................................................................................................................... 10
8 1534184 Upper Housing ........................................................................................................ 1
9 1534188 Bearing .................................................................................................................... 1
10 1534189 Plate ........................................................................................................................ 1
11 1534190 Bolt .......................................................................................................................... 14
12 1534191 Centering Bush ....................................................................................................... 2
13 1534287 Housing ................................................................................................................... 1
14 1534193 Cover ....................................................................................................................... 1
15 1479433 Oil Plug.................................................................................................................... 1
16 1534194 Washer .................................................................................................................... 1
17 1534197 Gear ........................................................................................................................ 1
18 1534198 Bearing .................................................................................................................... 1
19 1534199 Ring Nut .................................................................................................................. 1
20 1534200 Gear ........................................................................................................................ 1
21 1534290 Bearing .................................................................................................................... 2
22 1534202 Shim (1mm)............................................................................................................. 1
22 1534203 Shim (1.1mm).......................................................................................................... 1
22 1534204 Shim (1.2mm).......................................................................................................... 1
22 1534205 Shim (1.22mm)........................................................................................................ 1
22 1534206 Shim (1.24mm)........................................................................................................ 1
22 1534207 Shim (1.26mm)........................................................................................................ 1
22 1534208 Shim (1.28mm)........................................................................................................ 1
22 1534209 Shim (1.3mm).......................................................................................................... 1
23 1534291 Spacer ..................................................................................................................... 1
24 1534210 Shim (1.8mm).......................................................................................................... 1
24 1534211 Shim (1.85mm)........................................................................................................ 1
24 1534212 Shim (1.9mm).......................................................................................................... 1
24 1534213 Shim (1.95mm)........................................................................................................ 1
24 1534214 Shim (2mm)............................................................................................................. 1
24 1534215 Shim (2.05mm)........................................................................................................ 1
24 1534216 Shim (2.1mm).......................................................................................................... 1
24 1534218 Shim (2.15mm)........................................................................................................ 1
25 1534219 Bevel Gear and Pinion Set ...................................................................................... 1
26 1534220 Wheel Shaft............................................................................................................. 1
27 1534221 Cover ....................................................................................................................... 1
28 1497284 Seal (Wheel Shaft) .................................................................................................. 1
29 1534222 Bearing .................................................................................................................... 1
30 1534223 Shim (4.15mm)........................................................................................................ 1
30 1534224 Shim (4.175mm)...................................................................................................... 1
30 1534225 Shim (4.2mm).......................................................................................................... 1
30 1534226 Shim (4.225mm)...................................................................................................... 1
30 1534227 Shim (4.25mm)........................................................................................................ 1
30 1534228 Shim (4.275mm)...................................................................................................... 1
30 1534229 Shim (4.3mm).......................................................................................................... 1

©2003 HYSTER COMPANY See Service Manual 1-15

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

MASTER DRIVE UNIT ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

30 1534230 Shim (4.325mm)...................................................................................................... 1

30 1534231 Shim (4.35mm)........................................................................................................ 1
30 1534232 Shim (4.375mm)...................................................................................................... 1
30 1534233 Shim (4.4mm).......................................................................................................... 1
30 1534234 Shim (4.45mm)........................................................................................................ 1
30 1534235 Shim (4.5mm).......................................................................................................... 1
30 1534236 Shim (4.55mm)........................................................................................................ 1
31 1519014 Ring Nut .................................................................................................................. 1
32 1534249 Bearing .................................................................................................................... 1
33 1534237 Shim (.90mm).......................................................................................................... 1
33 1534238 Shim (.95mm).......................................................................................................... 1
33 1534239 Shim (1mm)............................................................................................................. 1
33 1534240 Shim (1.05mm)........................................................................................................ 1
33 1534241 Shim (1.1mm).......................................................................................................... 1
33 1534242 Shim (1.2mm).......................................................................................................... 1
33 1534243 Shim (1.22mm)........................................................................................................ 1
33 1534244 Shim (1.24mm)........................................................................................................ 1
33 1534245 Shim (1.26mm)........................................................................................................ 1
33 1534246 Shim (1.28mm)........................................................................................................ 1
33 1534247 Shim (1.3mm).......................................................................................................... 1
34 1534248 Spacer ..................................................................................................................... 1
35 1497280 Oil Fill Plug .............................................................................................................. 1
36 1497282 Oil Fill Gasket .......................................................................................................... 1
a 1534250 Nut........................................................................................................................... 4
a 1534251 Bolt .......................................................................................................................... 1

FOOTNOTES:
a Not Illustrated

1-16 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
NOTES

1-17
 UNIT CODE B454
NORTH AMERICA 03/2003

MASTER DRIVE UNIT (Figure 1-8)

1-18 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

MASTER DRIVE UNIT

ITEM PART NO. DESCRIPTION QTY

1 239503 Nut ............................................................................................................................... 10

2 292681 Lockwasher.................................................................................................................. 6
3 296424 Washer ........................................................................................................................ 9
4 320157 Washer ........................................................................................................................ 8
5 1343502 Capscrew..................................................................................................................... 5
6 1475398 Capscrew..................................................................................................................... 4
7 2039243 Wire Guide................................................................................................................... 1
8 2039303 Stud ............................................................................................................................. 4
9 2039316 Nut ............................................................................................................................... 4
10 a 293795 Capscrew..................................................................................................................... 4
11 2045094 Drive Unit (☞ Figure 1-7) ........................................................................................... 1
12 1479432 Seal ......................................................................................................................... 1
13 1479433 Oil Plug.................................................................................................................... 2
14 1534194 Washer .................................................................................................................... 1
15 2055944 Electric Brake............................................................................................................... 1
15 2045959 Key (Woodruff)............................................................................................................. 1
16 2041761 Traction Motor (150 Amp) ............................................................................................ 1
17 2040499 Wheel and Tire Assembly (Rubber)............................................................................. 1
17 2040753 Wheel and Tire Assembly (Poly).................................................................................. 1
17 2059612 Wheel and Tire Assembly (Siped Poly) ....................................................................... 1
18 2038719 Drive Wheel............................................................................................................. 1
19 2306688 Tire (Rubber) ........................................................................................................... 1
19 2037928 Tire (Poly) ................................................................................................................ 1
19 2059613 Tire (Siped Poly)...................................................................................................... 1
20 2045942 Enclosure Band ........................................................................................................... 1
21 132131 Clamp .......................................................................................................................... 1
22 887012 Pin ............................................................................................................................... 2
23 296174 Capscrew..................................................................................................................... 1
24 320159 Washer ........................................................................................................................ 1
25 292682 Lockwasher.................................................................................................................. 1
26 136692 Nut ............................................................................................................................... 1
27 216895 Static Strap .................................................................................................................. 1

FOOTNOTES:
a Maintenance use only.

©2003 HYSTER COMPANY See Service Manual 1-19

for service procedures.
NOTES

1-20
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2 ELECTRICAL SYSTEM

2 ELECTRICAL SYSTEM
 UNIT CODE B454
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SECTION 2
ELECTRICAL SYSTEM

DESCRIPTION PAGE

CONTROL PANEL ASSEMBLY............................................................................................................................ 2-2

ELECTRICAL ARRANGEMENT .......................................................................................................................... 2-4
TRACTION MOTOR ............................................................................................................................................. 2-6
WIRE HARNESS................................................................................................................................................ 2-10
MAIN TRUCK.................................................................................................................................................... 2-8

©2003 HYSTER COMPANY See Service Manual 2-1

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

CONTROL PANEL ASSEMBLY (Figure 2-1)

2-2 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

CONTROL PANEL ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

2054839 Control Panel Assembly .............................................................................................. 1

1 2055687 Contactor Panel....................................................................................................... 1
2 2055599 Controller................................................................................................................. 1
3 292680 Lockwasher ............................................................................................................. 6
4 287817 Capscrew ................................................................................................................ 6
5 2053769 Contactor................................................................................................................. 1
6 320156 Washer .................................................................................................................... 2
7 1356217 Fuse Holder (2-Way) ............................................................................................... 1
8 296355 Washer .................................................................................................................... 2
9 302008 Screw ...................................................................................................................... 2
10 1374793 Fuse (10 Amp)......................................................................................................... 2
11 1347314 Insulated Clamp ...................................................................................................... 1
12 320157 Washer .................................................................................................................... 2
13 292681 Lockwasher ............................................................................................................. 2
14 302060 Capscrew ................................................................................................................ 1
15 255578 Clamp ...................................................................................................................... 1
16 302057 Screw ...................................................................................................................... 1
17 361810 Fuse (300 Amp)....................................................................................................... 1
18 2053669 Buss Bar.................................................................................................................. 1
19 2054840 Wire Harness (Main) ............................................................................................... 1
20 2053787 Cable Assembly (F1) ............................................................................................... 1
21 2053788 Cable Assembly (F2) ............................................................................................... 1
22 2053792 Cable Assembly (A1)............................................................................................... 1
23 2053793 Cable Assembly (A2)............................................................................................... 1
24 2054155 Wire Harness .......................................................................................................... 1
25 2042675 Horn............................................................................................................................. 1
26 302044 Screw........................................................................................................................... 2
27 292680 Lockwasher.................................................................................................................. 4
28 320156 Washer ........................................................................................................................ 2
29 239503 Nut ............................................................................................................................... 4
30 292681 Lockwasher.................................................................................................................. 4
31 320157 Washer ........................................................................................................................ 4
32 296227 Capscrew..................................................................................................................... 4

©2003 HYSTER COMPANY See Service Manual 2-3

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

ELECTRICAL ARRANGEMENT (Figure 2-2)

2-4 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

ELECTRICAL ARRANGEMENT

ITEM PART NO. DESCRIPTION QTY

1 2054839 Control Panel Assembly .............................................................................................. 1

2 320157 Washer ........................................................................................................................ 4
3 292681 Lockwasher.................................................................................................................. 4
4 136681 Capscrew..................................................................................................................... 4
5 133484 Grommet...................................................................................................................... 2
6 292680 Lockwasher.................................................................................................................. 4
7 320156 Washer ........................................................................................................................ 2
8 302044 Screw........................................................................................................................... 2
9 264150 Nut ............................................................................................................................... 2
10 2042675 Horn............................................................................................................................. 1
11 2046546 Indicator ....................................................................................................................... 1
11 2311797 Plug ............................................................................................................................. 1
12 254007 Ignition Switch ............................................................................................................. 1
12 262798 Ignition Key.............................................................................................................. 1
12 b 2051870 Ignition Switch (Toggle) ............................................................................................... 1
a 2302672 Wire Tie ....................................................................................................................... 2
a 137852 Strap Clamp................................................................................................................. 8

FOOTNOTES:
a Not Illustrated
b Optional

©2003 HYSTER COMPANY See Service Manual 2-5

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

TRACTION MOTOR (Figure 2-3)

2-6 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

TRACTION MOTOR

ITEM PART NO. DESCRIPTION QTY

2041761 Traction Motor (150 Amp) ............................................................................................ 1

1 1500161 Armature ................................................................................................................. 1
2 1500162 Stator....................................................................................................................... 1
3 1500167 Brush Holder ........................................................................................................... 1
4 1500166 Brush and Spring Set .............................................................................................. 1
5 1500164 Plate ........................................................................................................................ 1
6 1500165 Bearing .................................................................................................................... 1
7 1500168 Bracket .................................................................................................................... 1
8 1500169 Cover Band ............................................................................................................. 1

©2003 HYSTER COMPANY See Service Manual 2-7

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

WIRE HARNESS (Figure 2-4)

MAIN TRUCK

2-8 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

WIRE HARNESS
MAIN TRUCK

ITEM PART NO. DESCRIPTION QTY

2054840 Wire Harness (Main).................................................................................................... 1

1 2049391 Connector................................................................................................................ 1
2 1369409 Connector................................................................................................................ 2
3 2034890 Connector................................................................................................................ 1
4 2037544 Connector................................................................................................................ 1
5 2048593 Connector................................................................................................................ 1
6 2303328 Connector................................................................................................................ 1
7 2309579 Socket (Molex)......................................................................................................... AR
8 2302852 Pin ........................................................................................................................... 3
9 2309579 Socket (Molex)......................................................................................................... 2
10 2058418 Connector................................................................................................................ 2
11 2059812 Connector................................................................................................................ 1

©2003 HYSTER COMPANY See Service Manual 2-9

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

WIRE HARNESS (Figure 2-5)

2-10 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

WIRE HARNESS

ITEM PART NO. DESCRIPTION QTY

2054155 Wire Harness (Contactor to Fuse Block) ..................................................................... 1

1 1301783 Connector .................................................................................................................... 2
2 222180 Cable ........................................................................................................................... 2
3 2303345 Terminal (Ring) ............................................................................................................ 2

©2003 HYSTER COMPANY See Service Manual 2-11

for service procedures.
NOTES

2-12
 UNIT CODE B454
03/2003 NORTH AMERICA

3 STEER HANDLE/BRAKE SYSTEM

3 STEER HANDLE/BRAKE SYSTEM

 UNIT CODE B454
03/2003 NORTH AMERICA

SECTION 3
STEER HANDLE/BRAKE SYSTEM

DESCRIPTION PAGE

ELECTRIC BRAKE............................................................................................................................................... 3-2

STEER HANDLE ARM ASSEMBLY ..................................................................................................................... 3-4
STEER HANDLE ASSEMBLY .............................................................................................................................. 3-6

©2003 HYSTER COMPANY See Service Manual 3-1

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

ELECTRIC BRAKE (Figure 3-1)

ITEM PART NO. DESCRIPTION QTY

2055944 Electric Brake............................................................................................................... 1

1 2046216 Disc ......................................................................................................................... 1
2 2046214 Brake Lining ............................................................................................................ 1
3 .. . . . Adjustment Tube...................................................................................................... 3
4 .. . . . Pressure Disk .......................................................................................................... 1
5 .. . . . Spring (Inner) .......................................................................................................... 4
6 2046215 Hub.......................................................................................................................... 1
7 .. . . . Magnet Body ........................................................................................................... 1
8 .. . . . Lockwasher.................................................................................................................. 3
9 .. . . . Capscrew ................................................................................................................ 3
10 .. . . . Spring (Outer) ......................................................................................................... 3
11 .. . . . Tappet...................................................................................................................... 4
12 .. . . . Adjusting Nut ........................................................................................................... 1
13 303294 Rectifier ....................................................................................................................... 1
a 2045942 Enclosure Band ........................................................................................................... 1

FOOTNOTES:
a Not Illustrated

3-2 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
NOTES

3-3
 UNIT CODE B454
NORTH AMERICA 03/2003

STEER HANDLE ARM ASSEMBLY (Figure 3-2)

3-4 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

STEER HANDLE ARM ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

1 2040527 Tube ............................................................................................................................. 1

2 16394 Capscrew..................................................................................................................... 1
3 18515 Washer ........................................................................................................................ 1
4 2042677 Shaft ............................................................................................................................ 1
5 2042691 Pin ............................................................................................................................... 1
6 2039858 Stud ............................................................................................................................. 2
7 2007882 Lube Fitting .................................................................................................................. 1
8 2044380 Bushing........................................................................................................................ 2
9 329069 Nut ............................................................................................................................... 2
10 296010 Capscrew..................................................................................................................... 2
11 320157 Washer ........................................................................................................................ 2
12 293780 Lockwasher.................................................................................................................. 2
13 1450356 Plug ............................................................................................................................. 2
14 1517668 Steer Handle Assembly (Standard) ............................................................................. 1
14 g 1534466 Steer Handle Assembly (Cold Storage)....................................................................... 1
14 f 1517669 Steer Handle Assembly (Cold Storage)....................................................................... 1
15 e 2059968 Gas Spring................................................................................................................... 1
15 d 2047141 Gas Spring................................................................................................................... 1
16 2049350 Microswitch .................................................................................................................. 1
17 2309196 Plate ............................................................................................................................ 1
17 1496663 Plate ............................................................................................................................ 1
18 220633 Screw........................................................................................................................... 2
19 2043856 Capscrew..................................................................................................................... 3
20 2056374 Switch Cover................................................................................................................ 1
20 136687 Nut........................................................................................................................... 1
20 2057922 Plate ........................................................................................................................ 1
21 353144 Capscrew..................................................................................................................... 1
22 292680 Lockwasher.................................................................................................................. 1
23 287817 Capscrew..................................................................................................................... 1
24 132131 Clamp .......................................................................................................................... 1
25 1486566 Clamp .......................................................................................................................... 1
26 1496661 Bracket......................................................................................................................... 1
26 a 1496664 Stud ......................................................................................................................... 2
26 a 320159 Washer .................................................................................................................... 5
26 a 136985 Capscrew ................................................................................................................ 1
26 a 136692 Nut........................................................................................................................... 4
27 2302569 Shim (0.030 in.) ........................................................................................................... 3
bc 2055656 Wire Harness............................................................................................................... 1

FOOTNOTES:
a For mounting to MDU.
b Not Illustrated
c Used on B455.
d ⇒ S/N PENDING PER ECN 84470
e S/N PENDING PER ECN 84470 ⇒
f ⇒ S/N PENDING PER ECN 84472
g S/N PENDING PER ECN 84472 ⇒

©2003 HYSTER COMPANY See Service Manual 3-5

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

STEER HANDLE ASSEMBLY (Figure 3-3)

3-6 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

STEER HANDLE ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

1517668 Steer Handle Assembly (Standard) ............................................................................. 1

b 1534466 Steer Handle Assembly (Cold Storage)....................................................................... 1
a 1517669 Steer Handle Assembly (Cold Storage)....................................................................... 1
1 1467778 Control Handle (Lower)................................................................................................ 3
1 2060004 Control Handle (Lower) (Cold Storage) ....................................................................... 1
2 2055488 Control Handle (Upper) ............................................................................................... 1
3 1498100 Interface Single Board (Standard) ............................................................................... 1
3 1498101 Interface Single Board (Cold Storage)......................................................................... 1
4 1466935 Camshaft ..................................................................................................................... 2
5 1466595 Bushing........................................................................................................................ 2
6 1466876 Butterfly Switch (LH) .................................................................................................... 1
7 320152 Washer ........................................................................................................................ 1
8 1499660 Screw........................................................................................................................... 1
9 1466607 Spring .......................................................................................................................... 1
10 1466875 Butterfly Switch (RH) ................................................................................................... 2
11 1467779 Switch Cover................................................................................................................ 1
11 1491262 Cover (Creep Speed)................................................................................................... 1
12 1466606 Spring .......................................................................................................................... 1
13 1467780 Switch Cover................................................................................................................ 1
14 1466877 Switch Assembly (LH/Center)...................................................................................... 2
14 1498102 Switch...................................................................................................................... 1
14 1503736 Button ...................................................................................................................... 1
15 2055619 Button .......................................................................................................................... 1
16 1507730 Proportional Switch Assembly (RH) ............................................................................ 2
17 1489471 Cover ........................................................................................................................... 3
18 1466605 Label (LH) .................................................................................................................... 1
19 1466604 Label (RH) ................................................................................................................... 1
20 1531075 Spring .......................................................................................................................... 1

1517670 Steer Handle Kit (Standard) (Includes Items 2-12, 14-20) .......................................... 1
1534467 Steer Handle Kit (Cold Storage) (Includes Items 2-12, 14-20) .................................... 1
1527024 Creep Speed Kit (Includes Items 11-12) ..................................................................... 1

FOOTNOTES:
a ⇒ S/N PENDING PER ECN 84472
b S/N PENDING PER ECN 84472 ⇒

©2003 HYSTER COMPANY See Service Manual 3-7

for service procedures.
NOTES

3-8
 UNIT CODE B454
03/2003 NORTH AMERICA

4 LOAD WHEEL

4 LOAD WHEEL
 UNIT CODE B454
03/2003 NORTH AMERICA

SECTION 4
LOAD WHEEL

DESCRIPTION PAGE

LOAD WHEEL ...................................................................................................................................................... 4-2

©2003 HYSTER COMPANY See Service Manual 4-1

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

LOAD WHEEL (Figure 4-1)

4-2 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

LOAD WHEEL

ITEM PART NO. DESCRIPTION QTY

1 2310757 Screw........................................................................................................................... 3
2 2034318 Plate ............................................................................................................................ 1
3 2045299 Locknut ........................................................................................................................ 1
4 a 15241 Cotter Pin..................................................................................................................... 2
5 1375415 Bearing ........................................................................................................................ 2
6 2058403 Load Wheel (6 in.) ....................................................................................................... 1
6 2034324 Load Wheel (7 in.) ....................................................................................................... 1
7 2034319 Wheel (6 in.) ............................................................................................................ 1
7 2034322 Wheel (7 in.) ............................................................................................................ 1
8 2055724 Poly Tire (6 in.) ........................................................................................................ 1
8 2034331 Poly Tire (7 in.) ........................................................................................................ 1
9 2034330 Shield........................................................................................................................... 1
10 221775 Washer ........................................................................................................................ 2
11 18262 Capscrew..................................................................................................................... 2
12 2034329 Bushing........................................................................................................................ 1
13 2034327 Screw (3/4 in.).............................................................................................................. 1
13 2034328 Screw (1-1/2 in.) .......................................................................................................... 1
14 2034326 Bracket......................................................................................................................... 1
15 2058402 Capscrew..................................................................................................................... 1
16 2058401 Washer ........................................................................................................................ 1

FOOTNOTES:
a The head of the cotter pins must be located within the center of the locknut.

©2003 HYSTER COMPANY See Service Manual 4-3

for service procedures.
NOTES

4-4
 UNIT CODE B454
03/2003 NORTH AMERICA

5 HYDRAULIC SYSTEM

5 HYDRAULIC SYSTEM
 UNIT CODE B454
03/2003 NORTH AMERICA

SECTION 5
HYDRAULIC SYSTEM

DESCRIPTION PAGE

HYDRAULIC POWER UNIT ................................................................................................................................. 5-2

HYDRAULIC PUMP AND MOTOR ASSEMBLY ................................................................................................... 5-4
TILT CYLINDER
ROD ENDS AND PINS ..................................................................................................................................... 5-6

©2003 HYSTER COMPANY See Service Manual 5-1

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

HYDRAULIC POWER UNIT (Figure 5-1)

5-2 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

HYDRAULIC POWER UNIT

ITEM PART NO. DESCRIPTION QTY

2054826 Hydraulic Pump and Motor .......................................................................................... 1

1 1529802 Motor ....................................................................................................................... 1
1 1529803 Brush Set ............................................................................................................ 1
1 1529843 Brush Plate ......................................................................................................... 1
2 1529844 Oldham Nut ............................................................................................................. 1
3 1529845 Pump Support ......................................................................................................... 1
4 1535244 Tank......................................................................................................................... 1
5 1512367 Clamp Assembly ................................................................................................. 1
6 1535245 Plug..................................................................................................................... 1
6 1474790 Elbow .............................................................................................................. 1
6 1474789 Breather Filter ................................................................................................. 1
7 1534531 Block with Proportional Valve .................................................................................. 1
8 1534532 Block without Proportional Valve......................................................................... 1
9 1529851 Proportional Valve............................................................................................... 1
10 1534533 Valve ................................................................................................................... 1
11 1534534 Valve Assembly............................................................................................... 1
12 1534535 Coil.................................................................................................................. 1
13 1535246 Block........................................................................................................................ 1
14 1535247 Block ................................................................................................................... 1
15 1534538 Valve ................................................................................................................... 1
16 1535248 Valve ................................................................................................................... 1
17 1535252 Tube......................................................................................................................... 1
17 1474797 Strainer ............................................................................................................... 1
18 1533889 Relief Valve ............................................................................................................. 1
19 1529856 Check Valve............................................................................................................. 1
20 a 1512370 Pump Repair Kit ...................................................................................................... 1

1535254 Mini Power Pack (Includes Items 2-20) ................................................................... 1

FOOTNOTES:
a Not Illustrated

©2003 HYSTER COMPANY See Service Manual 5-3

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

HYDRAULIC PUMP AND MOTOR ASSEMBLY (Figure 5-2)

5-4 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

HYDRAULIC PUMP AND MOTOR ASSEMBLY

ITEM PART NO. DESCRIPTION QTY

1 2054058 Isolator ......................................................................................................................... 2

2 2059208 Bracket......................................................................................................................... 1
3 2054826 Hydraulic Pump and Motor .......................................................................................... 1
4 18515 Washer ........................................................................................................................ 2
5 145639 Nut ............................................................................................................................... 2
6 292682 Lockwasher.................................................................................................................. 2
7 287854 Capscrew..................................................................................................................... 2
8 2055284 Support ........................................................................................................................ 1
9 320157 Washer ........................................................................................................................ 2
10 292681 Lockwasher.................................................................................................................. 2
11 176640 Capscrew..................................................................................................................... 2
12 239503 Nut ............................................................................................................................... 2
13 170204 Capscrew..................................................................................................................... 2
14 2054042 Fitting........................................................................................................................... 2
15 2054059 Fitting........................................................................................................................... 1
16 2055306 Foam............................................................................................................................ 1
a 2055351 Cable Assembly (Positive) ........................................................................................... 1
a 2055352 Cable Assembly (Negative) ......................................................................................... 1
a 2055650 Harness ....................................................................................................................... 1
a 2055628 Harness (with Sideshift)............................................................................................... 1
a 2055626 Jumper......................................................................................................................... 2

FOOTNOTES:
a Not Illustrated

©2003 HYSTER COMPANY See Service Manual 5-5

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

TILT CYLINDER (Figure 5-3)

ROD ENDS AND PINS

ITEM PART NO. DESCRIPTION QTY

1 2302034 Rod End....................................................................................................................... 2

2 216877 Nut ............................................................................................................................... 2
3 2021834 Washer ........................................................................................................................ 2
4 2306221 Tilt Cylinder (5 Back/4 Forward)................................................................................ 2
5 2034332 Cotter Pin..................................................................................................................... 4
6 2304004 Washer ........................................................................................................................ 4
7 2308848 Pin ............................................................................................................................... 2
8 293652 Capscrew..................................................................................................................... 2
9 292513 Capscrew..................................................................................................................... 2
10 292682 Lockwasher.................................................................................................................. 2
11 2303829 Plate ............................................................................................................................ 2
12 2034333 Lube Fitting.................................................................................................................. 2
13 2310277 Rod End Pin ................................................................................................................ 2

5-6 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

6 MAST-TWO STAGE LIMITED FREE-LIFT

6 MAST-TWO STAGE LIMITED FREE-LIFT

 UNIT CODE B454
03/2003 NORTH AMERICA

SECTION 6
MAST-TWO STAGE LIMITED FREE-LIFT

DESCRIPTION PAGE

CHAINS, PINS, AND ANCHORS

TWO STAGE LIMITED FREE-LIFT................................................................................................................... 6-4
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 6-6
INNER AND OUTER MAST
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 6-2
LIFT
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 6-8
LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 6-10

©2003 HYSTER COMPANY See Service Manual 6-1

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

INNER AND OUTER MAST (Figure 6-1)

TWO STAGE LIMITED FREE-LIFT

6-2 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

INNER AND OUTER MAST

TWO STAGE LIMITED FREE-LIFT

W25-30ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2597 mm 2851 mm 3156 mm 3613 mm 3816 mm
ITEM 1 2 3 4 (102.2 in.) (112.2 in.) (124.3 in.) (142.2 in.) (150.2 in.)
Mast A732 A732 A732 A732 A732
Group Number 2597 2851 3156 3613 3816
1 Outer Mast 2309519 2304801 2306543 2302687 2307705
2 Inner Mast 2311192 2305606 2306582 2304273 2302685

W40ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2496 mm 2750 mm 3054 mm 3512 mm 3715 mm
ITEM 1 2 3 4 (98.3 in.) (108.3 in.) (120.2 in.) (138.3 in.) (146.3 in.)
Mast A778 A778 A778 A778 A778
Group Number 2496 2750 3054 3512 3715
1 Outer Mast 2309519 2304801 2306543 2302687 2307705
2 Inner Mast 2311192 2305606 2306582 2304273 2302685

ITEM PART NO. DESCRIPTION QTY

1 a .. . . . Outer Mast................................................................................................................... 1
2 a .. . . . Inner Mast.................................................................................................................... 1
3 2310526 Bushing........................................................................................................................ 2
4 2033826 Screw........................................................................................................................... 4
5 2033827 Nut ............................................................................................................................... 4
6 2033828 Load Roller .................................................................................................................. 4
7 1374797 Snap Ring.................................................................................................................... 4
8 2033829 Plug ............................................................................................................................. 4
9 296009 Capscrew..................................................................................................................... 1

FOOTNOTES:
a Refer to Table

©2003 HYSTER COMPANY See Service Manual 6-3

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

CHAINS, PINS, AND ANCHORS (Figure 6-2)

TWO STAGE LIMITED FREE-LIFT

6-4 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

CHAINS, PINS, AND ANCHORS

TWO STAGE LIMITED FREE-LIFT

W25-30ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2597 mm 2851 mm 3156 mm 3613 mm 3816 mm
ITEM 1 2 3 4 (102.2 in.) (112.2 in.) (124.3 in.) (142.2 in.) (150.2 in.)
Mast A732 A732 A732 A732 A732
Group Number 2597 2851 3156 3613 3816
10 Chain 2306536 2310424 2305053 2307797 2310470

W40ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2496 mm 2750 mm 3054 mm 3512 mm 3715 mm
ITEM 1 2 3 4 (98.3 in.) (108.3 in.) (120.2 in.) (138.3 in.) (146.3 in.)
Mast A778 A778 A778 A778 A778
Group Number 2496 2750 3054 3512 3715
10 Chain 2308714 2309082 2305105 2308217 2306092

ITEM PART NO. DESCRIPTION QTY

1 1374797 Snap Ring.................................................................................................................... 2

2 287837 Capscrew..................................................................................................................... 2
2 292683 Lockwasher.................................................................................................................. 2
3 2303818 Support Sheave ........................................................................................................... 2
4 2304409 Shaft ............................................................................................................................ 1
5 2304814 Spacer ......................................................................................................................... 2
6 2305093 Sheave......................................................................................................................... 2
7 124633 Ball Bearing ................................................................................................................. 2
8 2304093 Snap Ring.................................................................................................................... 2
9 2033841 Washer (Special) ......................................................................................................... 2
10 a .. . . . Chain ........................................................................................................................... 2
11 15212 Cotter Pin..................................................................................................................... 4
12 2309214 Pin ............................................................................................................................... 2
13 2307145 Chain Anchor ............................................................................................................... 2
14 292600 Nut ............................................................................................................................... 2
15 2303194 Lockwasher (Special) .................................................................................................. 4
16 2305973 Pin ............................................................................................................................... 2
17 2303092 Chain Anchor ............................................................................................................... 2
18 198209 Snap Ring.................................................................................................................... 2
19 2305757 Lube Fitting .................................................................................................................. 2
20 2302624 Cotter Pin..................................................................................................................... 2
21 171350 Lubricant...................................................................................................................... AR
22 178297 Degreaser .................................................................................................................... AR
23 599737 Wear Scale .................................................................................................................. 1

FOOTNOTES:
a Refer to Table

©2003 HYSTER COMPANY See Service Manual 6-5

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

HEADER HOSE (Figure 6-3)

TWO STAGE LIMITED FREE-LIFT

6-6 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

HEADER HOSE
TWO STAGE LIMITED FREE-LIFT

W25-30ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2597 mm 2851 mm 3156 mm 3613 mm 3816 mm
ITEM 1 2 3 4 (102.2 in.) (112.2 in.) (124.3 in.) (142.2 in.) (150.2 in.)
Mast A732 A732 A732 A732 A732
Group Number 2597 2851 3156 3613 3816
4 Hose 2034408 2034596 2034410 2034411 2034412

W40ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2496 mm 2750 mm 3054 mm 3512 mm 3715 mm
ITEM 1 2 3 4 (98.3 in.) (108.3 in.) (120.2 in.) (138.3 in.) (146.3 in.)
Mast A778 A778 A778 A778 A778
Group Number 2496 2750 3054 3512 3715
4 Hose 2034408 2034596 2034410 2034411 2034412

ITEM PART NO. DESCRIPTION QTY

1 2302046 Sheave (Half)............................................................................................................... 2

2 136687 Nut ............................................................................................................................... 2
3 2302960 Screw........................................................................................................................... 2
4 a .. . . . Hose ............................................................................................................................ 2
5 16457 Fitting........................................................................................................................... 2
6 2034401 Anchor ......................................................................................................................... 1
7 292514 Capscrew..................................................................................................................... 2
8 292682 Lockwasher.................................................................................................................. 2
9 2034402 Manifold Block ............................................................................................................. 1
10 2034403 Capscrew..................................................................................................................... 2
11 292682 Lockwasher.................................................................................................................. 2
12 16540 Fitting........................................................................................................................... 2
12 16483 O-Ring ..................................................................................................................... 2
13 2054867 Hose (W25, 30ZC)....................................................................................................... 2
13 2055473 Hose (W40ZC)............................................................................................................. 2
14 16999 Fitting........................................................................................................................... 1

FOOTNOTES:
a Refer to Table

©2003 HYSTER COMPANY See Service Manual 6-7

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

LIFT (Figure 6-4)

TWO STAGE LIMITED FREE-LIFT

6-8 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

LIFT
TWO STAGE LIMITED FREE-LIFT

ITEM PART NO. DESCRIPTION QTY

1 292514 Capscrew..................................................................................................................... 1
2 2305142 Washer ........................................................................................................................ 1
3 .. . . . Lift Cylinder (☞ Figure 6-5) ........................................................................................ 1
4 2059614 Hose (W25-30ZC) ....................................................................................................... 1
4 2060872 Hose (W25-30ZC) ....................................................................................................... 1
4 2060873 Hose (W40ZC)............................................................................................................. 1
5 16569 Fitting........................................................................................................................... 1
5 16485 O-Ring (Face Seal).................................................................................................. 1
6 2304577 Flow Regulator (10.0 G.P.M.)....................................................................................... 1
7 2310888 Housing ....................................................................................................................... 1
8 1151213 Fitting........................................................................................................................... 1
8 16485 O-Ring (Face Seal).................................................................................................. 2

©2003 HYSTER COMPANY See Service Manual 6-9

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

LIFT CYLINDER (Figure 6-5)

TWO STAGE LIMITED FREE-LIFT

6-10 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT

W25-30ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2597 mm 2851 mm 3156 mm 3613 mm
ITEM 1 2 3 4 (102.2 in.) (112.2 in.) (124.3 in.) (142.2 in.)
Mast A729 A729 A729 A729
Group Number 2597 2851 3156 3613
Lift Cylinder 2034704 2034705 2034706 2034707
10 Rod 2308580 2305652 2305848 2311781
11 Tube 2307588 2042981 2306187 2302664

W40ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 2496 mm 2750 mm 3054 mm 3512 mm 3715 mm
ITEM 1 2 3 4 (98.3 in.) (108.3 in.) (120.2 in.) (138.3 in.) (146.3 in.)
Mast A775 A775 A775 A775 A775
Group Number 2496 2750 3054 3512 3715
Lift Cylinder 2034713 2034714 2034715 2034716 2034717
10 Rod 2308580 2305652 2305848 2311781 2303761
11 Tube 2308919 2305980 2308597 2308382 2306373

ITEM PART NO. DESCRIPTION QTY

a .. . . . Lift Cylinder.................................................................................................................. 1
1 2310082 Gland....................................................................................................................... 1
2 .. . . . Wiper Ring............................................................................................................... 1
3 .. . . . Rod Seal.................................................................................................................. 1
4 .. . . . O-Ring ..................................................................................................................... 1
5 2303017 Screw ...................................................................................................................... 1
6 .. . . . O-Ring ..................................................................................................................... 1
7 .. . . . Back-Up Ring .......................................................................................................... 1
8 1361302 Screw ...................................................................................................................... 1
9 190877 Shim (0.005 in.) ........................................................................................................... 1
10 a .. . . . Rod.......................................................................................................................... 1
11 a .. . . . Tube......................................................................................................................... 1
12 .. . . . Wear Ring ............................................................................................................... 1
13 186061 Packing Lubricant ........................................................................................................ AR

2307819 Cylinder Seal Kit (Includes Items 2-4, 6-7, 12) ............................................................ 1

FOOTNOTES:
a Refer to Table

©2003 HYSTER COMPANY See Service Manual 6-11

for service procedures.
NOTES

6-12
 UNIT CODE B454
03/2003 NORTH AMERICA

7 MAST-T HREE STAGE FULL FREE-LIFT

7 MAST-THREE STAGE FULL FREE-LIFT

 UNIT CODE B454
03/2003 NORTH AMERICA

SECTION 7
MAST-THREE STAGE FULL FREE-LIFT

DESCRIPTION PAGE

CHAINS, PINS AND ANCHORS

THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-4
FREE LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-6
HEADER HOSE
THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-8
INNER, INTERMEDIATE, AND OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 7-2
LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-12
MAIN FREE-LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................. 7-14

©2003 HYSTER COMPANY See Service Manual 7-1

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

INNER, INTERMEDIATE, AND OUTER MAST (Figure 7-1)

THREE STAGE FULL FREE-LIFT

7-2 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

INNER, INTERMEDIATE, AND OUTER MAST

THREE STAGE FULL FREE-LIFT

W25-30ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3951 mm 4332 mm 4789 mm 5475 mm 5780 mm
ITEM 1 2 3 4 (155.6 in.) (170.6 in.) (188.5 in.) (215.6 in.) (227.6 in.)
Mast A733 A733 A733 A733 A733
Group Number 3951 4332 4789 5475 5780
1 Outer Mast 2304175 2311020 2309547 2305880 2311057
2 Intermediate Mast 2306690 2310601 2304445 2310954 2309938
3 Inner Mast 2305541 2304398 2307327 2305489 2310833

W40ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3849 mm 4230 mm 4688 mm 5373 mm 5678 mm
ITEM 1 2 3 4 (151.5 in.) (166.5 in.) (184.6 in.) (211.5 in.) (223.5 in.)
Mast A779 A779 A779 A779 A779
Group Number 3849 4230 4688 5373 5678
1 Outer Mast 2304175 2311020 2309547 2305880 2311057
2 Intermediate Mast 2306690 2310601 2304445 2310954 2309938
3 Inner Mast 2305541 2304398 2307327 2305489 2310833

ITEM PART NO. DESCRIPTION QTY

1 a .. . . . Outer Mast................................................................................................................... 1
2 a .. . . . Intermediate Mast........................................................................................................ 1
3 a .. . . . Inner Mast.................................................................................................................... 1
4 2033826 Screw........................................................................................................................... 8
5 2033827 Nut ............................................................................................................................... 8
6 2033828 Load Roller .................................................................................................................. 8
7 1374797 Snap Ring.................................................................................................................... 8
8 2033829 Plug ............................................................................................................................. 8
9 2310526 Bushing........................................................................................................................ 2
10 296009 Capscrew..................................................................................................................... 1
11 2310074 Pin ............................................................................................................................... 2

FOOTNOTES:
a Refer to Table

©2003 HYSTER COMPANY See Service Manual 7-3

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

CHAINS, PINS AND ANCHORS (Figure 7-2)

THREE STAGE FULL FREE-LIFT

7-4 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

CHAINS, PINS AND ANCHORS

THREE STAGE FULL FREE-LIFT

W25-30ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3951 mm 4332 mm 4789 mm 5475 mm 5780 mm
ITEM 1 2 3 4 (155.6 in.) (170.6 in.) (188.5 in.) (215.6 in.) (227.6 in.)
Mast A733 A733 A733 A733 A733
Group Number 3951 4332 4789 5475 5780
8 Chain (Rear) 2311752 2306536 2310424 2304189 2310442
17 Chain (Front) 2309709 2303567 2309714 2310038 2311388

W40ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3849 mm 4230 mm 4688 mm 5373 mm 5678 mm
ITEM 1 2 3 4 (151.5 in.) (166.5 in.) (184.6 in.) (211.5 in.) (223.5 in.)
Mast A779 A779 A779 A779 A779
Group Number 3849 4230 4688 5373 5678
8 Chain (Rear) 2311752 2306536 2310424 2304189 2310442
17 Chain (Front) 2309709 2303567 2309714 2310038 2311388

ITEM PART NO. DESCRIPTION QTY

1 39363 O-Ring ......................................................................................................................... 1

2 1374796 Snap Ring.................................................................................................................... 4
3 2304536 Support Sheave ........................................................................................................... 1
4 2304409 Shaft ............................................................................................................................ 1
5 2305093 Sheave......................................................................................................................... 4
6 124633 Ball Bearing ................................................................................................................. 4
7 2304093 Snap Ring.................................................................................................................... 4
8 a .. . . . Chain (Rear) ................................................................................................................ 2
9 15212 Cotter Pin..................................................................................................................... 12
10 2309214 Pin ............................................................................................................................... 6
11 2307145 Chain Anchor ............................................................................................................... 4
12 292600 Nut ............................................................................................................................... 8
13 2305973 Pin ............................................................................................................................... 2
14 2303092 Chain Anchor ............................................................................................................... 2
15 198209 Snap Ring.................................................................................................................... 2
16 2305757 Lube Fitting .................................................................................................................. 2
17 a .. . . . Chain (Front)................................................................................................................ 2
18 2303194 Lockwasher (Replace Only in Pairs)............................................................................ 8
19 2304814 Spacer ......................................................................................................................... 1
20 2033841 Washer (Special) ......................................................................................................... 2
21 2302624 Cotter Pin..................................................................................................................... 2
22 171350 Lubricant...................................................................................................................... AR
23 178297 Degreaser .................................................................................................................... AR
24 599737 Wear Scale .................................................................................................................. 1

FOOTNOTES:
a Refer to Table

©2003 HYSTER COMPANY See Service Manual 7-5

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

FREE LIFT CYLINDER (Figure 7-3)

THREE STAGE FULL FREE-LIFT

7-6 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

FREE LIFT CYLINDER

THREE STAGE FULL FREE-LIFT

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3951 mm 4332 mm 4789 mm 5475 mm 5780 mm
ITEM 1 2 3 4 (155.6 in.) (170.6 in.) (188.5 in.) (215.6 in.) (227.6 in.)
Mast A733 A733 A733 A733 A733
Group Number 3951 4332 4789 5475 5780
Lift Cylinder 2034830 2034831 2034833 2034840 2034841
6 Piston Rod 2306680 2308769 2305890 2303554 2310873
10 Tube 2303454 2302900 2302317 2311756 2303185

ITEM PART NO. DESCRIPTION QTY

a .. . . . Lift Cylinder.................................................................................................................. 1
1 .. . . . Wiper Ring............................................................................................................... 1
2 .. . . . Seal ......................................................................................................................... 1
3 2304256 Gland....................................................................................................................... 1
4 .. . . . Back-Up Ring .......................................................................................................... 1
5 .. . . . O-Ring ..................................................................................................................... 1
6 a .. . . . Piston Rod............................................................................................................... 1
7 .. . . . Wear Ring ............................................................................................................... 1
8 2302806 Ball .......................................................................................................................... 2
9 2305120 Plug ......................................................................................................................... 2
10 a .. . . . Tube......................................................................................................................... 1
11 2304531 Velocity Fuse (23 G.P.M.) ........................................................................................ 1
12 190887 Seal ......................................................................................................................... 1
13 295649 Screw (Special) ....................................................................................................... 1
14 186061 Packing Lubricant .................................................................................................... AR

2304259 Seal Kit (Includes Items 1-2, 4-5, 7, 12) ...................................................................... AR

FOOTNOTES:
a Refer to Table

©2003 HYSTER COMPANY See Service Manual 7-7

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

HEADER HOSE (Figure 7-4)

THREE STAGE FULL FREE-LIFT

7-8 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

HEADER HOSE
THREE STAGE FULL FREE-LIFT

W25-30ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3951 mm 4332 mm 4789 mm 5475 mm 5780 mm
ITEM 1 2 3 4 (155.6 in.) (170.6 in.) (188.5 in.) (215.6 in.) (227.6 in.)
Mast A733 A733 A733 A733 A733
Group Number 3951 4332 4789 5475 5780
10 Hose 2034439 2034440 2034441 2034442 2034443
11 Hose 2034444 2034445 2034446 2034447 2034448
18 Hose 2034434 2034435 2034436 2034437 2034438
19 Hose 2034429 2034430 2034431 2034432 2034433

W40ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3849 mm 4230 mm 4688 mm 5373 mm 5678 mm
ITEM 1 2 3 4 (151.5 in.) (166.5 in.) (184.6 in.) (211.5 in.) (223.5 in.)
Mast A779 A779 A779 A779 A779
Group Number 3849 4230 4688 5373 5678
10 Hose 2034439 2034440 2034441 2034442 2034443
11 Hose 2034444 2034445 2034446 2034447 2034448
18 Hose 2034434 2034435 2034436 2034437 2034438
19 Hose 2034429 2034430 2034431 2034432 2034433

ITEM PART NO. DESCRIPTION QTY

1 2303614 Sheave......................................................................................................................... 1
2 2309023 Sheave......................................................................................................................... 1
3 2034423 Spacer ......................................................................................................................... 1
4 2302017 Washer ........................................................................................................................ AR
5 15178 Washer ........................................................................................................................ 1
6 292537 Capscrew..................................................................................................................... 1
7 2302046 Sheave (Half)............................................................................................................... 2
8 2302960 Screw........................................................................................................................... 2
9 136687 Nut ............................................................................................................................... 2
10 a .. . . . Hose ............................................................................................................................ 1
11 a .. . . . Hose ............................................................................................................................ 1
12 16540 Fitting........................................................................................................................... 4
12 16483 O-Ring ..................................................................................................................... 1
13 16558 Fitting........................................................................................................................... 2
13 16483 O-Ring ..................................................................................................................... 1
14 2034421 Manifold ....................................................................................................................... 1
15 292682 Lockwasher.................................................................................................................. 2
16 292514 Capscrew..................................................................................................................... 2
17 134436 Fitting........................................................................................................................... 2
17 16482 O-Ring ..................................................................................................................... 1
18 a .. . . . Hose ............................................................................................................................ 1
19 a .. . . . Hose ............................................................................................................................ 1
20 16447 Fitting........................................................................................................................... 1

©2003 HYSTER COMPANY See Service Manual 7-9

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

HEADER HOSE
THREE STAGE FULL FREE-LIFT

ITEM PART NO. DESCRIPTION QTY

21 16457 Fitting ........................................................................................................................... 1

22 282678 Hose ............................................................................................................................ AR
22 316876 Fitting ........................................................................................................................... 4
23 16883 Fitting ........................................................................................................................... 1
24 2034422 Bracket......................................................................................................................... 1
25 292681 Lockwasher.................................................................................................................. 2
26 136681 Capscrew..................................................................................................................... 2
27 2034402 Manifold Block ............................................................................................................. 1
28 292682 Lockwasher.................................................................................................................. 2
29 2034403 Capscrew..................................................................................................................... 2

FOOTNOTES:
a Refer to Table

7-10 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
NOTES

7-11
 UNIT CODE B454
NORTH AMERICA 03/2003

LIFT CYLINDER (Figure 7-5)

THREE STAGE FULL FREE-LIFT

7-12 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

LIFT CYLINDER
THREE STAGE FULL FREE-LIFT

W25-30ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3951 mm 4332 mm 4789 mm 5475 mm 5780 mm
ITEM 1 2 3 4 (155.6 in.) (170.6 in.) (188.5 in.) (215.6 in.) (227.6 in.)
Mast A733 A733 A733 A733 A733
Group Number 3951 4332 4789 5475 5780
Lift Cylinder 2034804 2034805 2034806 2310695 2034813
5 Piston Rod 2303190 2309511 2303601 2307854 2303620
16 Tube 2306097 2308751 2302406 2305739 2303294

W40ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3849 mm 4230 mm 4688 mm 5373 mm 5678 mm
ITEM 1 2 3 4 (151.5 in.) (166.5 in.) (184.6 in.) (211.5 in.) (223.5 in.)
Mast A779 A779 A779 A779 A779
Group Number 3849 4230 4688 5373 5678
Lift Cylinder 2034815 2034816 2034817 2034819 2034820
5 Piston Rod 2303190 2309511 2303601 2307854 2303620
16 Tube 2309655 2310491 2310348 2303745 2311270

ITEM PART NO. DESCRIPTION QTY

a .. . . . Lift Cylinder.................................................................................................................. 2
1 .. . . . Wiper Ring............................................................................................................... 1
2 .. . . . Seal ......................................................................................................................... 2
3 2306042 Gland....................................................................................................................... 1
4 .. . . . O-Ring ..................................................................................................................... 1
5 a .. . . . Piston Rod............................................................................................................... 1
6 .. . . . Back-Up Ring .......................................................................................................... 1
7 .. . . . Wear Ring ............................................................................................................... 1
8 .. . . . O-Ring ..................................................................................................................... 1
9 297530 Check Valve............................................................................................................. 1
10 297531 Washer .................................................................................................................... 1
11 386684 Shim (0.005 in.) ....................................................................................................... AR
11 386683 Shim (0.007 in.) ....................................................................................................... AR
11 386682 Shim (0.020 in.) ....................................................................................................... AR
12 187388 Snap Ring................................................................................................................ 1
13 323103 Piston ...................................................................................................................... 1
14 58916 Snap Ring................................................................................................................ 1
15 2310149 Velocity Fuse (10 G.P.M.) ........................................................................................ 1
16 a .. . . . Tube......................................................................................................................... 1
17 186061 Packing Lubricant .................................................................................................... AR

2307071 Seal Kit (Includes Items 1-2, 4, 6-8) ............................................................................ AR

FOOTNOTES:
a Refer to Table

©2003 HYSTER COMPANY See Service Manual 7-13

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

MAIN FREE-LIFT (Figure 7-6)

THREE STAGE FULL FREE-LIFT

7-14 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

MAIN FREE-LIFT
THREE STAGE FULL FREE-LIFT

W25-30ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3951 mm 4332 mm 4789 mm 5475 mm 5780 mm
ITEM 1 2 3 4 (155.6 in.) (170.6 in.) (188.5 in.) (215.6 in.) (227.6 in.)
Mast A733 A733 A733 A733 A733
Group Number 3951 4332 4789 5475 5780
2 Hose 2306203 2308494 2310734 2302158 2310198

W40ZC

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION 3849 mm 4230 mm 4688 mm 5373 mm 5678 mm
ITEM 1 2 3 4 (151.5 in.) (166.5 in.) (184.6 in.) (211.5 in.) (223.5 in.)
Mast A779 A779 A779 A779 A779
Group Number 3849 4230 4688 5373 5678
2 Hose 2306203 2308494 2310734 2302158 2310198

ITEM PART NO. DESCRIPTION QTY

1 2310789 Spacer ......................................................................................................................... 2

2 a .. . . . Hose ............................................................................................................................ 1
3 2302927 Sheave......................................................................................................................... 1
4 3041265 Snap Ring.................................................................................................................... 1
5 2307814 Fitting........................................................................................................................... 1
6 .. . . . Free-Lift Cylinder ......................................................................................................... 1
7 2304531 Velocity Fuse (23 G.P.M.) ............................................................................................ 1
8 2308475 Clamp .......................................................................................................................... 1
9 15107 Nut ............................................................................................................................... 2
10 144416 Snap Ring.................................................................................................................... 2
11 2308990 Washer ........................................................................................................................ 2
12 2304287 Bushing........................................................................................................................ 2
13 2310054 Shim ............................................................................................................................ AR
14 287854 Capscrew..................................................................................................................... 4
15 2311241 Lockwasher.................................................................................................................. 4
16 320159 Washer ........................................................................................................................ 4
17 2308625 Guard........................................................................................................................... 2
18 .. . . . Lift Cylinder.................................................................................................................. 2
19 2310149 Velocity Fuse (10 G.P.M.) ............................................................................................ 1
20 2304249 Lock Plate (LH) ............................................................................................................ 1
21 2309463 Lock Plate (RH) ........................................................................................................... 1
22 136749 Capscrew..................................................................................................................... 4
23 320177 Washer ........................................................................................................................ 4
24 2305701 Hose ............................................................................................................................ 2
25 16578 Fitting........................................................................................................................... 1
25 16485 O-Ring (Face Seal).................................................................................................. 1
26 16560 Fitting........................................................................................................................... 1
26 16485 O-Ring (Face Seal).................................................................................................. 1
27 16559 Fitting........................................................................................................................... 1
27 16484 O-Ring ..................................................................................................................... 1
28 2306655 Flow Regulator (12 G.P.M.).......................................................................................... 1
©2003 HYSTER COMPANY See Service Manual 7-15
for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

MAIN FREE-LIFT
THREE STAGE FULL FREE-LIFT

ITEM PART NO. DESCRIPTION QTY

29 2308404 Housing ....................................................................................................................... 1

30 136704 Capscrew..................................................................................................................... 2
31 292681 Lockwasher.................................................................................................................. 2
32 320157 Washer ........................................................................................................................ 2

FOOTNOTES:
a Refer to Table

7-16 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

8 CARRIAGE

8 CARRIAGE
 UNIT CODE B454
03/2003 NORTH AMERICA

SECTION 8
CARRIAGE

DESCRIPTION PAGE

CARRIAGE
THREE STAGE FULL FREE-LIFT
W25ZC, W30ZC ............................................................................................................................................ 8-3
W40ZC .......................................................................................................................................................... 8-2
TWO STAGE LIMITED FREE-LIFT
W25ZC, W30ZC ............................................................................................................................................ 8-6
W40ZC .......................................................................................................................................................... 8-4

©2003 HYSTER COMPANY See Service Manual 8-1

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

CARRIAGE (Figure 8-1)

THREE STAGE FULL FREE-LIFT
W40ZC

ITEM PART NO. DESCRIPTION QTY

1 2310447 Carriage (Group No. 8620663).................................................................................... 1

2 2033826 Screw ...................................................................................................................... 2
3 2033827 Nut........................................................................................................................... 2
4 2033828 Load Roller .............................................................................................................. 6
5 1374797 Snap Ring................................................................................................................ 6
6 2033829 Plug ......................................................................................................................... 2

8-2 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

CARRIAGE (Figure 8-2)

THREE STAGE FULL FREE-LIFT
W25ZC, W30ZC

ITEM PART NO. DESCRIPTION QTY

1 2305936 Carriage (Group No. 8620648).................................................................................... 1

2 2033826 Screw ...................................................................................................................... 2
3 2033827 Nut........................................................................................................................... 2
4 2033828 Load Roller .............................................................................................................. 4
5 1374797 Snap Ring................................................................................................................ 4
6 2033829 Plug ......................................................................................................................... 4

©2003 HYSTER COMPANY See Service Manual 8-3

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

CARRIAGE (Figure 8-3)

TWO STAGE LIMITED FREE-LIFT
W40ZC

8-4 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

CARRIAGE
TWO STAGE LIMITED FREE-LIFT
W40ZC

ITEM PART NO. DESCRIPTION QTY

1 2033825 Carriage (Group No. 8620653).................................................................................... 1

2 2033826 Screw ...................................................................................................................... 4
3 2033827 Nut........................................................................................................................... 4
4 2033828 Load Roller .............................................................................................................. 6
5 1374797 Snap Ring................................................................................................................ 6
6 2033829 Plug ......................................................................................................................... 4

©2003 HYSTER COMPANY See Service Manual 8-5

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

CARRIAGE (Figure 8-4)

TWO STAGE LIMITED FREE-LIFT
W25ZC, W30ZC

ITEM PART NO. DESCRIPTION QTY

1 2033824 Carriage (Group No. 8620638).................................................................................... 1

2 2033826 Screw ...................................................................................................................... 4
3 2033827 Nut........................................................................................................................... 4
4 2033828 Load Roller .............................................................................................................. 4
5 1374797 Snap Ring................................................................................................................ 4
6 2033829 Plug ......................................................................................................................... 4

8-6 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

9 OPTIONS

9 OPTIONS
 UNIT CODE B454
03/2003 NORTH AMERICA

SECTION 9
OPTIONS

DESCRIPTION PAGE

BATTERY ROLLER .............................................................................................................................................. 9-2

HOSE TAKE UP
THREE STAGE
SINGLE FUNCTION...................................................................................................................................... 9-4
LOAD BACKREST AND FORKS
HOOK TYPE CARRIAGE ................................................................................................................................. 9-8
SIDE-SHIFT CARRIAGE .................................................................................................................................... 9-10
SIDE-SHIFT CYLINDER .................................................................................................................................... 9-12
ZAPI-HANDSET KIT........................................................................................................................................... 9-15
ZAPI-LAPTOP/PC KIT (WINDOWS) .................................................................................................................. 9-14

©2003 HYSTER COMPANY See Service Manual 9-1

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

BATTERY ROLLER (Figure 9-1)

9-2 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

BATTERY ROLLER

ITEM PART NO. DESCRIPTION QTY

1 2040462 Battery Tray.................................................................................................................. 1

2 2303911 Roller Assembly........................................................................................................... 4
3 16830 Capscrew..................................................................................................................... 2
4 15135 Washer ........................................................................................................................ 2
5 15158 Lockwasher.................................................................................................................. 2
6 15058 Nut ............................................................................................................................... 2
7 2035085 Retaining Gate............................................................................................................. 2
8 2058425 Spacer Plate ................................................................................................................ 2
9 18723 Capscrew..................................................................................................................... 4
10 15154 Lockwasher.................................................................................................................. 4
11 15054 Nut ............................................................................................................................... 4

©2003 HYSTER COMPANY See Service Manual 9-3

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

HOSE TAKE UP (Figure 9-2)

THREE STAGE
SINGLE FUNCTION

9-4 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

HOSE TAKE UP
THREE STAGE
SINGLE FUNCTION

LIFT HEIGHT TO BOTTOM OF FORKS

DESCRIPTION
ITEM 1 2 3 4
Mast
Group Number - - - - -
Hose Take-Up 2034424 2034425 2034426 2034427 2034428
Assembly
1 Hose 2034429 2034430 2034431 2034432 2034433
2 Hose 2034434 2034435 2034436 2034437 2034438
3 Hose 2034439 2034440 2034441 2034442 2034443
4 Hose 2034444 2034445 2034446 2034447 2034448

ITEM PART NO. DESCRIPTION QTY

b .. . . . Hose Take-Up Assembly ............................................................................................. 1

1 b .. . . . Hose ............................................................................................................................ 1
2 b .. . . . Hose ............................................................................................................................ 1
3 b .. . . . Hose ............................................................................................................................ 1
4 b .. . . . Hose ............................................................................................................................ 1
5 16540 Fitting........................................................................................................................... 4
5 16483 O-Ring ..................................................................................................................... 1
6 16558 Fitting........................................................................................................................... 2
6 16483 O-Ring ..................................................................................................................... 1
7 2034421 Manifold ....................................................................................................................... 1
7 134436 Fitting........................................................................................................................... 2
7 16482 O-Ring ..................................................................................................................... 1
8 292514 Capscrew..................................................................................................................... 2
8 292682 Lockwasher.................................................................................................................. 2
9 2034402 Manifold Block ............................................................................................................. 1
10 2034403 Capscrew..................................................................................................................... 2
10 292682 Lockwasher.................................................................................................................. 2
11 2034422 Bracket......................................................................................................................... 1
12 136681 Capscrew..................................................................................................................... 2
12 292681 Lockwasher.................................................................................................................. 2
12 16883 Fitting........................................................................................................................... 1
13 16457 Fitting........................................................................................................................... 1
14 16447 Fitting........................................................................................................................... 1
15 2302046 Sheave (Half)............................................................................................................... 2
15 2302960 Screw........................................................................................................................... 2
15 136687 Nut ............................................................................................................................... 2
16 2303614 Sheave......................................................................................................................... 1
17 2034423 Spacer ......................................................................................................................... 1
18 2309023 Sheave......................................................................................................................... 1
19 15178 Washer ........................................................................................................................ 1
19 2302017 Washer ........................................................................................................................ AR
20 292537 Capscrew..................................................................................................................... 1

©2003 HYSTER COMPANY See Service Manual 9-5

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

HOSE TAKE UP
THREE STAGE
SINGLE FUNCTION

ITEM PART NO. DESCRIPTION QTY

21 a 282678 Hose ............................................................................................................................ AR

22 a 316876 Fitting ........................................................................................................................... 4

FOOTNOTES:
a Connecting Hoses to Control Valve
b Refer to Table

9-6 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
NOTES

9-7
 UNIT CODE B454
NORTH AMERICA 03/2003

LOAD BACKREST AND FORKS (Figure 9-3)

HOOK TYPE CARRIAGE

9-8 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

LOAD BACKREST AND FORKS

HOOK TYPE CARRIAGE

ITEM PART NO. DESCRIPTION QTY

1 1523913 Load Backrest.............................................................................................................. 1

2 1343990 Capscrew (4000 lb. with sideshift)............................................................................... 4
2 2034347 Capscrew (4000 lb. without sideshift).......................................................................... 4
2 2034348 Capscrew (3000 lb.)..................................................................................................... 4
3 221771 Washer ........................................................................................................................ 4
4 300937 Nut ............................................................................................................................... 4
5 384211 Fork (36 in.) -1.5.......................................................................................................... 2
5 1334303 Fork (36 in.) -1.75........................................................................................................ 2
5 384213 Fork (42 in.) -1.5.......................................................................................................... 2
5 1334304 Fork (42 in.) -1.75........................................................................................................ 2
5 384214 Fork (48 in.) -1.5.......................................................................................................... 2
5 1334306 Fork (48 in.) -1.75........................................................................................................ 2
6 1523732 Knob ............................................................................................................................ 1
7 1523733 Pin ............................................................................................................................... 1
8 1500782 Spring .......................................................................................................................... 1
9 1523734 Retainer Pin ................................................................................................................. 1

©2003 HYSTER COMPANY See Service Manual 9-9

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

SIDE-SHIFT CARRIAGE (Figure 9-4)

9-10 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

SIDE-SHIFT CARRIAGE

ITEM PART NO. DESCRIPTION QTY

1399035 Side-Shift Assembly..................................................................................................... 1

1 1396455 Bearing (Top)........................................................................................................... 1
2 1399001 Support.................................................................................................................... 1
3 1371289 Capscrew ................................................................................................................ 2
4 313828 Nut........................................................................................................................... 4
5 1358809 Rod (Optional) ......................................................................................................... 2
6 313828 Nut (Optional) .......................................................................................................... 2
6 302400 Locknut (Optional) ................................................................................................... 2
7 1358821 Shim (0.020 in.) ....................................................................................................... 4
8 1360125 Cylinder Assembly (Group No. 8601301) ............................................................... 1
9 16041 Lube Fitting.............................................................................................................. 3
10 1355521 Apron (Top).............................................................................................................. 1
11 1378050 Apron (Lower).......................................................................................................... 1
12 1378060 Bearing (Lower)....................................................................................................... 1
13 293704 Capscrew ................................................................................................................ 4
13 16600 Screw ...................................................................................................................... 4
13 340044 Gripnail .................................................................................................................... 4
14 296431 Washer .................................................................................................................... 4
15 1396426 Shim ........................................................................................................................ 6
16 16538 Fitting....................................................................................................................... 2
16 16481 O-Ring ..................................................................................................................... 1
17 2034399 Hose ........................................................................................................................ 2
18 201766 Fitting....................................................................................................................... 2
18 16483 O-Ring ..................................................................................................................... 1

2056300 Hose Kit (Includes Items 16-18) .................................................................................. 1

©2003 HYSTER COMPANY See Service Manual 9-11

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

SIDE-SHIFT CYLINDER (Figure 9-5)

9-12 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

SIDE-SHIFT CYLINDER

KEY:
A: Long Stroke
B: Short Stroke

QTY
ITEM PART NO. DESCRIPTION A B

1360125 Cylinder Assembly ............................................................................................... 1 ..

1 636851 Wiper Ring....................................................................................................... 2 2
2 2310768 Gland............................................................................................................... 2 2
3 1383037 Seal ................................................................................................................. 2 2
4 153919 Back-Up Ring .................................................................................................. 2 2
5 55407 O-Ring ............................................................................................................. 2 2
6 2303300 Spacer ............................................................................................................. .. 2
7 2306755 Seal ................................................................................................................. 1 1
8 2309719 Rod.................................................................................................................. 1 1
9 2311471 Tube................................................................................................................. 1 1
10 383789 Thread Sealer.................................................................................................. AR AR

2311624 Seal Kit (Includes Items 1, 3-5, 7) ....................................................................... 1 1

©2003 HYSTER COMPANY See Service Manual 9-13

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

ZAPI-LAPTOP/PC KIT (WINDOWS) (Figure 9-6)

ITEM PART NO. DESCRIPTION QTY

2049640 Laptop/PC Kit (ZAPI) (Windows) ................................................................................. 1
1 2047806 Adaptor Harness ..................................................................................................... 1
2799290 Cable and Software Kit (Windows).......................................................................... 1
2 .. . . . Cable................................................................................................................... 1
3 .. . . . Software .............................................................................................................. 1

9-14 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

ZAPI-HANDSET KIT (Figure 9-7)

ITEM PART NO. DESCRIPTION QTY

2049815 Handset Kit (ZAPI) (Includes Item ) ............................................................................. 1

1 2792832 Handset Console..................................................................................................... 1
2 2047806 Adaptor Harness ..................................................................................................... 1

©2003 HYSTER COMPANY See Service Manual 9-15

for service procedures.
NOTES

9-16
 UNIT CODE B454
03/2003 NORTH AMERICA

10 NUMERICAL INDEX
 UNIT CODE B454
03/2003 NORTH AMERICA

SECTION 10
NUMERICAL INDEX
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
15054 1-7 5 16560 7-15 26 190887 7-7 12 5-6 10
9-3 11 16569 6-9 5 198209 6-5 18 6-7 8
15056 1-9 9 16578 7-15 25 7-5 15 6-7 11
15058 1-11 5 16600 9-11 13 201766 9-11 18 7-9 15
1-13 5 16828 1-9 6 216877 5-6 2 7-10 28
9-3 6 16830 9-3 3 216895 1-19 27 9-5 8
15107 7-15 9 16883 7-10 23 220359 1-7 3 9-5 10
15134 1-9 7 9-5 12 220633 3-5 18 292683 6-5 2
15135 9-3 4 16999 6-7 14 221712 1-9 4 293652 5-6 8
15154 1-7 4 17276 1-13 2 221771 9-9 3 293704 9-11 13
9-3 10 18262 4-3 11 221775 4-3 10 293780 3-5 12
15156 1-9 8 18515 3-5 3 222180 2-11 2 293795 1-19 10
15158 1-9 3 5-5 4 227089 1-5 7 295649 7-7 13
1-11 4 18599 1-11 2 239503 1-19 1 296009 6-3 9
1-13 4 18723 9-3 9 2-3 29 7-3 10
9-3 5 39363 7-5 1 5-5 12 296010 3-5 10
15178 1-9 2 55407 9-13 5 254007 2-5 12 296174 1-19 23
1-11 3 58916 7-13 14 255578 2-3 15 296227 2-3 32
1-13 3 124633 6-5 7 262798 2-5 12 296355 2-3 8
7-9 5 7-5 6 264150 1-7 6 296424 1-19 3
9-5 19 132131 1-19 21 2-5 9 296431 9-11 14
15212 6-5 11 3-5 24 282678 7-10 22 297530 7-13 9
7-5 9 133484 2-5 5 9-5 21 297531 7-13 10
15241 4-3 4 134436 7-9 17 287817 2-3 4 300937 9-9 4
16041 9-11 9 9-5 7 3-5 23 302008 2-3 9
16394 3-5 2 136681 2-5 4 287837 6-5 2 302044 2-3 26
16447 7-9 20 7-10 26 287854 5-5 7 2-5 8
9-5 14 9-5 12 7-15 14 302057 2-3 16
16457 6-7 5 136687 3-5 20 288835 1-7 1 302060 2-3 14
7-9 21 6-7 2 292513 5-6 9 302400 9-11 6
9-5 13 7-9 9 292514 6-7 7 303294 3-2 13
16481 9-11 16 9-5 15 6-9 1 313828 9-11 4
16482 7-9 17 136692 1-19 26 7-9 16 9-11 6
9-5 7 3-5 26 9-5 8 316876 7-10 22
16483 6-7 12 136704 7-16 30 292537 7-9 6 9-6 22
7-9 12 136749 7-15 22 9-5 20 320152 3-7 7
7-9 13 136985 3-5 26 292600 6-5 14 320156 2-3 6
9-5 5 137852 2-5 13 7-5 12 2-3 28
9-5 6 144416 7-15 10 292680 2-3 3 2-5 7
9-11 18 145639 5-5 5 2-3 27 320157 1-19 4
16484 7-15 27 153919 9-13 4 2-5 6 2-3 12
16485 6-9 5 170204 5-5 13 3-5 22 2-3 31
6-9 8 171350 6-5 21 292681 1-19 2 2-5 2
7-15 25 7-5 22 2-3 13 3-5 11
7-15 26 176640 5-5 11 2-3 30 5-5 9
16538 9-11 16 178297 6-5 22 2-5 3 7-16 32
16540 6-7 12 7-5 23 5-5 10 320159 1-19 24
7-9 12 186061 6-11 13 7-10 25 3-5 26
9-5 5 7-7 14 7-16 31 7-15 16
16558 7-9 13 7-13 17 9-5 12 320177 7-15 23
9-5 6 187388 7-13 12 292682 1-19 25 323103 7-13 13
16559 7-15 27 190877 6-11 9 5-5 6 329069 3-5 9
©2003 HYSTER COMPANY See Service Manual 10-1
for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

NUMERICAL INDEX (Continued)

PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM

335989 1-5 5 1399035 9-11 1517668 3-5 14 1534211 1-15 24

335991 1-5 6 1450356 3-5 13 3-7 1534212 1-15 24
340044 9-11 13 1466595 3-7 5 1517669 3-5 14 1534213 1-15 24
353144 3-5 21 1466604 3-7 19 3-7 1534214 1-15 24
361810 2-3 17 1466605 3-7 18 1517670 3-7 21 1534215 1-15 24
383789 9-13 10 1466606 3-7 12 1519014 1-16 31 1534216 1-15 24
384211 9-9 5 1466607 3-7 9 1523732 9-9 6 1534218 1-15 24
384213 9-9 5 1466875 3-7 10 1523733 9-9 7 1534219 1-15 25
384214 9-9 5 1466876 3-7 6 1523734 9-9 9 1534220 1-15 26
386682 7-13 11 1466877 3-7 14 1523913 9-9 1 1534221 1-15 27
386683 7-13 11 1466935 3-7 4 1525537 1-5 9 1534222 1-15 29
386684 7-13 11 1467778 3-7 1 1525539 1-5 9 1534223 1-15 30
389688 1-3 10 1467779 3-7 11 1525540 1-5 8 1534224 1-15 30
389692 1-3 7 1467780 3-7 13 1525541 1-5 8 1534225 1-15 30
599737 6-5 23 1468390 1-5 1 1527024 3-7 23 1534226 1-15 30
7-5 24 1474789 5-3 6 1529042 1-3 4 1534227 1-15 30
636851 9-13 1 1474790 5-3 6 1529043 1-3 13 1534228 1-15 30
887012 1-19 22 1474797 5-3 17 1529802 5-3 1 1534229 1-15 30
1151213 6-9 8 1475398 1-19 6 1529803 5-3 1 1534230 1-15 30
1195971 1-7 1 1479130 1-3 5 1529843 5-3 1 1534231 1-16 30
1301783 2-11 1 1479432 1-15 2 1529844 5-3 2 1534232 1-16 30
1334303 9-9 5 1-19 12 1529845 5-3 3 1534233 1-16 30
1334304 9-9 5 1479433 1-15 15 1529851 5-3 9 1534234 1-16 30
1334306 9-9 5 1-19 13 1529856 5-3 19 1534235 1-16 30
1343502 1-19 5 1486566 3-5 25 1531075 3-7 20 1534236 1-16 30
1343990 9-9 2 1489471 3-7 17 1533889 5-3 18 1534237 1-16 33
1347314 2-3 11 1491262 3-7 11 1534179 1-15 1 1534238 1-16 33
1355521 9-11 10 1494689 1-3 9 1534181 1-15 4 1534239 1-16 33
1356217 2-3 7 1496661 3-5 26 1534182 1-15 5 1534240 1-16 33
1358809 9-11 5 1496663 3-5 17 1534183 1-15 6 1534241 1-16 33
1358821 9-11 7 1496664 3-5 26 1534184 1-15 8 1534242 1-16 33
1360125 9-11 8 1497280 1-16 35 1534186 1-15 7 1534243 1-16 33
9-13 1497282 1-16 36 1534188 1-15 9 1534244 1-16 33
1361302 6-11 8 1497284 1-15 28 1534189 1-15 10 1534245 1-16 33
1369409 2-9 2 1498100 3-7 3 1534190 1-15 11 1534246 1-16 33
1371289 9-11 3 1498101 3-7 3 1534191 1-15 12 1534247 1-16 33
1374793 2-3 10 1498102 3-7 14 1534193 1-15 14 1534248 1-16 34
1374796 7-5 2 1499660 3-7 8 1534194 1-15 16 1534249 1-16 32
1374797 6-3 7 1500161 2-7 1 1-19 14 1534250 1-16 37
6-5 1 1500162 2-7 2 1534197 1-15 17 1534251 1-16 38
7-3 7 1500164 2-7 5 1534198 1-15 18 1534286 1-15 3
8-2 5 1500165 2-7 6 1534199 1-15 19 1534287 1-15 13
8-3 5 1500166 2-7 4 1534200 1-15 20 1534290 1-15 21
8-5 5 1500167 2-7 3 1534202 1-15 22 1534291 1-15 23
8-6 5 1500168 2-7 7 1534203 1-15 22 1534466 3-5 14
1375415 4-3 5 1500169 2-7 8 1534204 1-15 22 3-7
1378050 9-11 11 1500782 9-9 8 1534205 1-15 22 1534467 3-7 22
1378060 9-11 12 1503736 3-7 14 1534206 1-15 22 1534531 5-3 7
1383037 9-13 3 1506716 1-3 6 1534207 1-15 22 1534532 5-3 8
1396426 9-11 15 1507730 3-7 16 1534208 1-15 22 1534533 5-3 10
1396455 9-11 1 1512367 5-3 5 1534209 1-15 22 1534534 5-3 11
1399001 9-11 2 1512370 5-3 20 1534210 1-15 24 1534535 5-3 12

10-2 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

NUMERICAL INDEX (Continued)

PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM

1534538 5-3 15 2034347 9-9 2 2034441 7-9 10 2040499 1-19 17

1535244 5-3 4 2034348 9-9 2 9-5 3 2040527 3-5 1
1535245 5-3 6 2034380 1-5 10 2034442 7-9 10 2040664 1-5 4
1535246 5-3 13 2034381 1-5 11 9-5 3 2040753 1-19 17
1535247 5-3 14 2034382 1-5 12 2034443 7-9 10 2041761 1-19 16
1535248 5-3 16 2034399 9-11 17 9-5 3 2-7
1535252 5-3 17 2034401 6-7 6 2034444 7-9 11 2042675 2-3 25
1535254 5-3 21 2034402 6-7 9 9-5 4 2-5 10
2007882 3-5 7 7-10 27 2034445 7-9 11 2042677 3-5 4
2021834 5-6 3 9-5 9 9-5 4 2042691 3-5 5
2033589 1-7 2 2034403 6-7 10 2034446 7-9 11 2042981 6-11 11
2033824 8-6 1 7-10 29 9-5 4 2043856 3-5 19
2033825 8-5 1 9-5 10 2034447 7-9 11 2044380 3-5 8
2033826 6-3 4 2034408 6-7 4 9-5 4 2044484 1-3 8
7-3 4 2034410 6-7 4 2034448 7-9 11 2045094 1-15
8-2 2 2034411 6-7 4 9-5 4 1-19 11
8-3 2 2034412 6-7 4 2034556 1-9 1 2045299 4-3 3
8-5 2 2034421 7-9 14 2034596 6-7 4 2045942 1-19 20
8-6 2 9-5 7 2034704 6-11 3-2 14
2033827 6-3 5 2034422 7-10 24 2034705 6-11 2045959 1-19 15
7-3 5 9-5 11 2034706 6-11 2046214 3-2 2
8-2 3 2034423 7-9 3 2034707 6-11 2046215 3-2 6
8-3 3 9-5 17 2034713 6-11 2046216 3-2 1
8-5 3 2034424 9-5 2034714 6-11 2046546 2-5 11
8-6 3 2034425 9-5 2034715 6-11 2047141 3-5 15
2033828 6-3 6 2034426 9-5 2034716 6-11 2047806 9-14 1
7-3 6 2034427 9-5 2034717 6-11 9-15 2
8-2 4 2034428 9-5 2034804 7-13 2048593 2-9 5
8-3 4 2034429 7-9 19 2034805 7-13 2049350 3-5 16
8-5 4 9-5 1 2034806 7-13 2049391 2-9 1
8-6 4 2034430 7-9 19 2034813 7-13 2049640 9-14
2033829 6-3 8 9-5 1 2034815 7-13 2049815 9-15 0
7-3 8 2034431 7-9 19 2034816 7-13 2050774 1-3 8
8-2 6 9-5 1 2034817 7-13 2051870 2-5 12
8-3 6 2034432 7-9 19 2034819 7-13 2053653 1-3 3
8-5 6 9-5 1 2034820 7-13 2053669 2-3 18
8-6 6 2034433 7-9 19 2034830 7-7 2053769 2-3 5
2033841 6-5 9 9-5 1 2034831 7-7 2053787 2-3 20
7-5 20 2034434 7-9 18 2034833 7-7 2053788 2-3 21
2034124 1-3 2 9-5 2 2034840 7-7 2053792 2-3 22
2034318 4-3 2 2034435 7-9 18 2034841 7-7 2053793 2-3 23
2034319 4-3 7 9-5 2 2034890 2-9 3 2053813 1-7 1
2034322 4-3 7 2034436 7-9 18 2035085 9-3 7 2053814 1-7 1
2034324 4-3 6 9-5 2 2036141 1-5 2 2054042 5-5 14
2034326 4-3 14 2034437 7-9 18 2037544 2-9 4 2054058 5-5 1
2034327 4-3 13 9-5 2 2037928 1-19 19 2054059 5-5 15
2034328 4-3 13 2034438 7-9 18 2038719 1-19 18 2054155 2-3 24
2034329 4-3 12 9-5 2 2039243 1-19 7 2-11
2034330 4-3 9 2034439 7-9 10 2039303 1-19 8 2054342 1-3 16
2034331 4-3 8 9-5 3 2039316 1-19 9 2054826 5-3
2034332 5-6 5 2034440 7-9 10 2039858 3-5 6 5-5 3
2034333 5-6 12 9-5 3 2040462 9-3 1 2054831 1-3 17

©2003 HYSTER COMPANY See Service Manual 10-3

for service procedures.
 UNIT CODE B454
NORTH AMERICA 03/2003

NUMERICAL INDEX (Continued)

PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM

2054839 2-3 2302672 2-5 13 2304814 6-5 5 2308217 6-5 10

2-5 1 2302685 6-3 2 7-5 19 2308382 6-11 11
2054840 2-3 19 2302687 6-3 1 2305053 6-5 10 2308404 7-15 29
2-9 2302806 7-7 8 2305093 6-5 6 2308468 1-3 1
2054867 6-7 13 2302852 2-9 8 7-5 5 2308475 7-15 8
2055284 5-5 8 2302900 7-7 10 2305105 6-5 10 2308494 7-15 2
2055306 5-5 16 2302927 7-15 3 2305120 7-7 9 2308580 6-11 10
2055351 5-5 17 2302960 6-7 3 2305142 6-9 2 2308597 6-11 11
2055352 5-5 18 7-9 8 2305489 7-3 3 2308625 7-15 17
2055473 6-7 13 9-5 15 2305541 7-3 3 2308714 6-5 10
2055488 3-7 2 2303017 6-11 5 2305606 6-3 2 2308751 7-13 16
2055599 2-3 2 2303092 6-5 17 2305652 6-11 10 2308769 7-7 6
2055619 3-7 15 7-5 14 2305701 7-15 24 2308848 5-6 7
2055626 5-5 21 2303185 7-7 10 2305739 7-13 16 2308919 6-11 11
2055628 5-5 20 2303190 7-13 5 2305757 6-5 19 2308990 7-15 11
2055650 5-5 19 2303194 6-5 15 7-5 16 2309023 7-9 2
2055656 3-5 28 7-5 18 2305848 6-11 10 9-5 18
2055687 2-3 1 2303294 7-13 16 2305880 7-3 1 2309082 6-5 10
2055724 4-3 8 2303300 9-13 6 2305890 7-7 6 2309196 3-5 17
2055918 1-3 14 2303328 2-9 6 2305936 8-3 1 2309214 6-5 12
2055944 1-19 15 2303345 2-11 3 2305973 6-5 16 7-5 10
3-2 2303454 7-7 10 7-5 13 2309463 7-15 21
2056300 9-11 19 2303554 7-7 6 2305980 6-11 11 2309511 7-13 5
2056374 3-5 20 2303567 7-5 17 2306042 7-13 3 2309519 6-3 1
2057922 3-5 20 2303601 7-13 5 2306092 6-5 10 2309547 7-3 1
2058401 4-3 16 2303614 7-9 1 2306097 7-13 16 2309579 2-9 7
2058402 4-3 15 9-5 16 2306187 6-11 11 2-9 9
2058403 4-3 6 2303620 7-13 5 2306203 7-15 2 2309655 7-13 16
2058418 2-9 10 2303745 7-13 16 2306221 5-6 4 2309709 7-5 17
2058425 9-3 8 2303761 6-11 10 2306348 1-9 5 2309714 7-5 17
2059208 5-5 2 2303818 6-5 3 2306373 6-11 11 2309719 9-13 8
2059612 1-19 17 2303829 5-6 11 2306536 6-5 10 2309938 7-3 2
2059613 1-19 19 2303911 9-3 2 7-5 8 2310038 7-5 17
2059614 6-9 4 2304004 5-6 6 2306543 6-3 1 2310054 7-15 13
2059812 2-9 11 2304093 6-5 8 2306582 6-3 2 2310074 7-3 11
2059968 3-5 15 7-5 7 2306655 7-15 28 2310082 6-11 1
2060004 3-7 1 2304175 7-3 1 2306680 7-7 6 2310149 7-13 15
2060872 6-9 4 2304189 7-5 8 2306688 1-19 19 7-15 19
2060873 6-9 4 2304249 7-15 20 2306690 7-3 2 2310198 7-15 2
2302017 7-9 4 2304256 7-7 3 2306755 9-13 7 2310277 5-6 13
9-5 19 2304259 7-7 15 2306899 1-5 3 2310348 7-13 16
2302034 5-6 1 2304273 6-3 2 2307071 7-13 18 2310424 6-5 10
2302046 6-7 1 2304287 7-15 12 2307145 6-5 13 7-5 8
7-9 7 2304398 7-3 3 7-5 11 2310442 7-5 8
9-5 15 2304409 6-5 4 2307327 7-3 3 2310447 8-2 1
2302158 7-15 2 7-5 4 2307400 1-3 12 2310470 6-5 10
2302317 7-7 10 2304445 7-3 2 2307588 6-11 11 2310491 7-13 16
2302406 7-13 16 2304531 7-7 11 2307705 6-3 1 2310526 6-3 3
2302569 3-5 27 7-15 7 2307797 6-5 10 7-3 9
2302624 6-5 20 2304536 7-5 3 2307814 7-15 5 2310601 7-3 2
7-5 21 2304577 6-9 6 2307819 6-11 14 2310695 7-13
2302664 6-11 11 2304801 6-3 1 2307854 7-13 5 2310734 7-15 2

10-4 See Service Manual ©2003 HYSTER COMPANY

for service procedures.
 UNIT CODE B454
03/2003 NORTH AMERICA

NUMERICAL INDEX (Continued)

PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM

2310757 4-3 1 2310954 7-3 2 2311388 7-5 17 2311797 2-5 11

2310768 9-13 2 2311020 7-3 1 2311471 9-13 9 2770775 1-3 15
2310789 7-15 1 2311057 7-3 1 2311624 9-13 11 2792832 9-15 1
2310833 7-3 3 2311192 6-3 2 2311752 7-5 8 2799290 9-14 2
2310873 7-7 6 2311241 7-15 15 2311756 7-7 10 3041265 7-15 4
2310888 6-9 7 2311270 7-13 16 2311781 6-11 10

©2003 HYSTER COMPANY See Service Manual 10-5

for service procedures.
NOTES

10-6