2015 Hyster E4.0XN E5.0XN E5.0XNS E5.5XN (A099) Parts Manual – PDF DOWNLOAD
DESCRIPTION:
2015 Hyster E4.0XN E5.0XN E5.0XNS E5.5XN (A099) Parts Manual – PDF DOWNLOAD
WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:
1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.
WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:
3. Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 11-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
6. Parts Super session Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.
- Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (Figure 10)
TABLE OF CONTENTS:
2015 Hyster E4.0XN E5.0XN E5.0XNS E5.5XN (A099) Parts Manual – PDF DOWNLOAD
Frame……………………………………………………………………………………………… 19
OPERATOR MODULE…………………………………………………………………………………. 22
COUNTERWEIGHT…………………………………………………………………………………… 24
COUNTERWEIGHT COVER WITH RAPID CHARGE OPTION……………………………………………………….. 25
OVERHEAD GUARD………………………………………………………………………………….. 26
FLOORPLATES AND STEPS……………………………………………………………………………. 28
HOOD WITH STANDARD OVERHEAD GUARD – E5.0-5.5XN …………………………………………………….. 30
HOOD WITH STANDARD OVERHEAD GUARD – E4.0-E5.0XNS …………………………………………………… 32
FULL SUSPENSION SEAT MANUAL HYDRAULIC – SHEET 1 OF 2 ……………………………………………….. 34
FULL SUSPENSION SEAT MANUAL HYDRAULIC – SHEET 2 OF 2 ……………………………………………….. 38
FULL SUSPENSION SEAT ELECTRO HYDRAULIC – SHEET 1 OF 2 ………………………………………………. 40
FULL SUSPENSION SEAT ELECTRO-HYDRAULIC – SHEET 2 OF 2 ………………………………………………. 44
ARMREST SLIDER ASSEMBLY………………………………………………………………………….. 46
BATTERY COMPARTMENT AND COVERS HORIZONTAL BATTERY REMOVAL (→ 4/2013) ………………………………… 48
BATTERY COMPARTMENT AND COVERS HORIZONTAL BATTERY REMOVAL (4/2013 →) ………………………………… 52
BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL – E5.0-5.5XN (→ 4/2013) ……………………… 56
BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL – E5.0-5.5XN (4/2013 →) ……………………… 58
BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL – E4.0-E5.0XNS ……………………………….. 60
DASH AND STEERING COLUMN COVERS FIXED COLUMN……………………………………………………….. 62
DASH AND STEERING COLUMN COVERS TELESCOPIC COLUMN…………………………………………………… 64
FENDERS………………………………………………………………………………………… 66
FORKS STANDARD TAPER CLASS III AND CLASS IV………………………………………………………… 67
FORKS STANDARD TAPER OPTIONAL – CLASS III AND CLASS IV ……………………………………………… 69
LOAD BACKREST EXTENSION………………………………………………………………………….. 72
NAMEPLATES AND LABELS SHEET 1 OF 2………………………………………………………………… 74
NAMEPLATES AND LABELS SHEET 2 OF 2………………………………………………………………… 76
NAMEPLATES AND LABELS HYDRAULIC CONTROL FUNCTIONS…………………………………………………… 78
ELECTRICAL SYSTEM…………………………………………………………………………………… 81
ELECTRICAL ARRANGEMENT…………………………………………………………………………… 86
BATTERY CONNECTOR WITH STANDARD OVERHEAD GUARD – E5.0-5.5XN (→ 11/2014) …………………………….. 88
BATTERY CONNECTOR WITH STANDARD OVERHEAD GUARD – E5.0-5.5XN (11/2014 →) …………………………….. 90
BATTERY CONNECTOR WITH STANDARD OVERHEAD GUARD – E4.0-5.0XNS (→ 11/2014) ……………………………. 92
BATTERY CONNECTOR WITH STANDARD OVERHEAD GUARD – E4.0-5.0XNS (11/2014 →) ……………………………. 94
BATTERY CONNECTOR WITH FLAT OVERHEAD GUARD (→ 11/2014) …………………………………………….. 96
BATTERY CONNECTOR WITH FLAT OVERHEAD GUARD (11/2014 →) …………………………………………….. 98
CONTROL PANELS AND CONTACTORS……………………………………………………………………..100
CONTACTOR AND FUSE ASSEMBLY……………………………………………………………………….101
CONTACTOR ASSEMBLY UL-E…………………………………………………………………………..102
CONTROLLER ASSEMBLY PUMP MOTOR (→ 11/2014) ………………………………………………………..104
CONTROLLER ASSEMBLY TRACTION MOTOR (→ 11/2014) …………………………………………………….106
CONTROLLER ASSEMBLY PUMP AND TRACTION (11/2014 →) ………………………………………………….108
POWER CABLES E4.0-5.5XN (→ 11/2014) ………………………………………………………………110
POWER CABLES E4.0-5.0 XNS (11/2014 →) …………………………………………………………….112
POWER CABLES E5.0XNS (→ 11/2014) …………………………………………………………………114
POWER CABLES E5.0-5.5 XN (11/2014 →) ……………………………………………………………..116
DISPLAY GROUP AND HARNESS…………………………………………………………………………118
LIGHTS………………………………………………………………………………………….120
MINI-LEVER CONTROLS 3 FUNCTION…………………………………………………………………….124
MINI-LEVER CONTROLS 4 FUNCTION…………………………………………………………………….126
TILT SENSOR GROUP………………………………………………………………………………..129
TURN SIGNAL……………………………………………………………………………………..130
VEHICLE SYSTEM MANAGER……………………………………………………………………………131
WIRE HARNESS RH LIGHT WITH STANDARD DISPLAY (→ 10/2013) …………………………………………….132
WIRE HARNESS RH LIGHT WITH STANDARD DISPLAY (10/2013 →) …………………………………………….133
WIRE HARNESS RH LIGHT WITH FREEZER DISPLAY (→ 10/2013) ……………………………………………..134
WIRE HARNESS RH LIGHT WITH FREEZER DISPLAY (10/2013 →) ……………………………………………..136
WIRE HARNESS EMERGENCY DISCONNECT………………………………………………………………….137
WIRE HARNESS FRONT SWITCH…………………………………………………………………………138
WIRE HARNESS LIGHTS – LEFT HAND W/O TURN SIGNALS (→ 4/2013) ………………………………………..140
WIRE HARNESS LEFT HAND – WITHOUT TURN SIGNALS (10/2013 →) ………………………………………….142
WIRE HARNESS LIGHTS – LEFT HAND W/TURN SIGNALS (→ 10/2013) …………………………………………144
WIRE HARNESS LEFT HAND – WITH TURN SIGNALS (10/2013 →) …………………………………………….146
WIRE HARNESS MAIN – MANUAL-HYDRAULIC SHEET 1 OF 3 (→ 11/2014) ………………………………………148
WIRE HARNESS MAIN – MANUAL-HYDRAULIC SHEET 2 OF 3 (→ 11/2014) ………………………………………152
WIRE HARNESS MAIN – MANUAL-HYDRAULIC SHEET 3 OF 3 (→ 11/2014) ………………………………………156
MAIN WIRE HARNESS MANUAL HYDRAULIC – SHEET 1 OF 3 (11/2014 →) ………………………………………160
MAIN WIRE HARNESS MANUAL HYDRAULIC – SHEET 2 OF 3 (11/2014 →) ………………………………………164
MAIN WIRE HARNESS MANUAL HYDRAULIC – SHEET 3 OF 3 (11/2014 →) ………………………………………168
WIRE HARNESS MAIN – ELECTRO-HYDRAULIC SHEET 1 OF 3 (→ 11/2014) ……………………………………..172
WIRE HARNESS MAIN – ELECTRO-HYDRAULIC SHEET 2 OF 3 (→ 11/2014) ……………………………………..176
WIRE HARNESS MAIN – ELECTRO-HYDRAULIC SHEET 3 OF 3 (→ 11/2014) ……………………………………..180
MAIN WIRE HARNESS ELECTRIC HYDRAULIC – SHEET 1 OF 3 (11/2014 →) …………………………………….184
MAIN WIRE HARNESS ELECTRIC HYDRAULIC – SHEET 2 OF 3 (11/2014 →) …………………………………….188
MAIN WIRE HARNESS ELECTRIC HYDRAULIC – SHEET 3 OF 3 (11/2014 →) …………………………………….192
WIRE HARNESS MAIN LIGHTS CHASSIS – 48V …………………………………………………………….196
WIRE HARNESS MAIN LIGHTS CHASSIS – 80V …………………………………………………………….200
WIRE HARNESS MAIN CHASSIS – W/O LIGHTS …………………………………………………………….204
WIRE HARNESS MANUAL INTERLOCK……………………………………………………………………..206
WIRE HARNESS SEAT – E-HYDRAULIC …………………………………………………………………..208
WIRE HARNESS SEAT – E-HYDRAULIC WITH SEAT BELT SEQUENCE MODULE ……………………………………….210
WIRE HARNESS SEAT – MANUAL HYDRAULIC ………………………………………………………………211
WIRE HARNESS SEAT – MANUAL HYDRAULIC WITH SEAT BELT SEQUENCE MODULE …………………………………..212
WIRE HARNESS STEERING COLUMN………………………………………………………………………214
WIRE HARNESS SYNCHRONOUS STEERING………………………………………………………………….216
WIRE HARNESS TURN SIGNAL SWITCH……………………………………………………………………218
WIRE HARNESS TURN SIGNAL………………………………………………………………………….220
WIRE HARNESS JUMPER………………………………………………………………………………222
DRIVE UNIT………………………………………………………………………………………….223
DRIVE AXLE AND ATTACHING PARTS…………………………………………………………………….226
DRIVE AXLE ASSEMBLY WET BRAKE – RIGHT AND LEFT HAND HUBS …………………………………………….228
DRIVE AXLE ASSEMBLY WET BRAKE – BRAKES AND DIFFERENTIAL ……………………………………………..232
DRIVE AXLE ASSEMBLY WET BRAKE – INPUT PINION CARRIER ………………………………………………..235
DIFFERENTIAL ASSEMBLY WET BRAKE……………………………………………………………………237
TRACTION MOTOR…………………………………………………………………………………..238
DRIVE TIRE AND WHEEL E4.0XN-5.0XNS…………………………………………………………………239
DRIVE TIRE AND WHEEL E5.0-5.5XN……………………………………………………………………240
STEERING SYSTEM……………………………………………………………………………………..241
STEER AXLE WITHOUT SENSOR…………………………………………………………………………244
STEER AXLE CYLINDER………………………………………………………………………………248
STEER TIRE AND WHEEL……………………………………………………………………………..250
STEERING WHEEL AND COLUMN FIXED……………………………………………………………………251
STEERING WHEEL AND COLUMN TELESCOPIC……………………………………………………………….252
STEER COLUMN FIXED – Remove this one ………………………………………………………………254
STEER COLUMN TELESCOPIC – Remove this one ………………………………………………………….256
STEERING COLUMN ASSEMBLY FIXED (→ 10/2013) ………………………………………………………..258
STEERING COLUMN ASSEMBLY FIXED (10/2013 →) ………………………………………………………..260
STEERING COLUMN ASSEMBLY TELESCOPIC (→ 10/2013) ……………………………………………………262
STEERING COLUMN ASSEMBLY TELESCOPIC (10/2013 →) ……………………………………………………263
STEER PUMP ASSEMBLY………………………………………………………………………………264
STEER PUMP ASSEMBLY………………………………………………………………………………266
STEERING ACCUMULATOR……………………………………………………………………………..268
BRAKE/ACCELERATOR SYSTEM……………………………………………………………………………..269
BRAKE SYSTEM…………………………………………………………………………………….272
BRAKE ASSEMBLY…………………………………………………………………………………..274
PARKING BRAKE VALVE………………………………………………………………………………276
MASTER CYLINDER………………………………………………………………………………….277
ACCELERATOR PEDAL ASSEMBLY (STANDARD)………………………………………………………………278
ACCELERATOR PEDAL ASSEMBLY (MONOTROL)………………………………………………………………279
HYDRAULIC SYSTEM…………………………………………………………………………………….281
HYDRAULIC SUPPLY AND RETURN PAGE 1 OF 2…………………………………………………………….284
HYDRAULIC SUPPLY AND RETURN PAGE 2 OF 2…………………………………………………………….286
HYDRAULIC TANK AND ATTACHING PARTS…………………………………………………………………288
HYDRAULIC HOSES STEERING………………………………………………………………………….290
HYDRAULIC PUMP AND MOTOR MOUNTING WET SPLINE DRIVE 29 CC (11/2014 →) ………………………………..292
HYDRAULIC PUMP AND MOTOR MOUNTING WET SPLINE DRIVE 33 CC…………………………………………….293
HYDRAULIC PUMP 29 cc (11/2014 →) …………………………………………………………………294
HYDRAULIC PUMP 33 cc……………………………………………………………………………..296
HYDRAULIC MOTOR ASSEMBLY………………………………………………………………………….298
HYDRAULIC MOTOR ASSEMBLY WITH 29 CC PUMP (11/2014 →) ………………………………………………300
HYDRAULIC MOTOR ASSEMBLY WITH 33 CC PUMP (11/2014 →) ……………………………………………….302
MANUAL CONTROL LEVERS…………………………………………………………………………….304
HYDRAULIC CONTROL VALVE AND FITTINGS MANUAL HYDRAULIC – THREE AND FOUR FUNCTION ………………………..307
HYDRAULIC CONTROL VALVE ASSEMBLY MANUAL HYDRAULIC – THREE AND FOUR FUNCTION ……………………………309
HYDRAULIC CONTROL VALVE LIFT, TILT, AND AUXILIARY – MANUAL HYDRAULIC ………………………………….312
HYDRAULIC CONTROL VALVE INLET SECTION – MANUAL HYDRAULIC …………………………………………….314
HYDRAULIC CONTROL VALVE AND FITTINGS ELECTRO-HYDRAULIC – THREE AND FOUR FUNCTION ……………………….316
HYDRAULIC CONTROL VALVE ASSEMBLY ELECTRO-HYDRAULIC – THREE AND FOUR FUNCTION …………………………..318
HYDRAULIC CONTROL VALVE LIFT, TILT, AND AUXILIARY – ELECTRO-HYDRAULIC …………………………………320
HYDRAULIC CONTROL VALVE INLET SECTION – ELECTRO-HYDRAULIC ……………………………………………322
TILT CYLINDER AND ATTACHING PARTS………………………………………………………………….324
TILT CYLINDER……………………………………………………………………………………326
Mast-Two Stage Limited Free-Lift………………………………………………………………………329
OUTER MAST TWO STAGE LIMITED FREE-LIFT……………………………………………………………..332
INNER MAST TWO STAGE LIMITED FREE-LIFT……………………………………………………………..336
MAIN LIFT TWO STAGE LIMITED FREE-LIFT (→ 10/2013) ………………………………………………….340
MAIN LIFT TWO STAGE LIMITED FREE-LIFT (10/2013 →) ………………………………………………….344
MAIN LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT – E4.0XN ……………………………………………..348
MAIN LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT – E5.0-5.5XN/E5.0XNS …………………………………..350
CARRIAGE TWO STAGE LIMITED FREE-LIFT……………………………………………………………….354
HEADER HOSE TWO STAGE LIMITED FREE-LIFT…………………………………………………………….356
INTEGRAL SIDE-SHIFT TWO STAGE LIMITED FREE LIFT CLASS IV – ORFS FITTINGS ………………………………362
Mast-Three Stage Full Free-Lift……………………………………………………………………….365
OUTER MAST THREE STAGE FULL FREE-LIFT (→ 10/2013) ………………………………………………….368
OUTER MAST THREE STAGE FULL FREE-LIFT (10/2013 →) ………………………………………………….372
INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT………………………………………………………..376
INNER MAST THREE STAGE FULL FREE-LIFT………………………………………………………………380
MAIN LIFT THREE STAGE FULL FREE-LIFT……………………………………………………………….382
MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT……………………………………………………….386
FREE-LIFT THREE STAGE FULL FREE-LIFT (→ 10/2013) …………………………………………………..390
FREE-LIFT THREE STAGE FULL FREE-LIFT (10/2013 →) …………………………………………………..394
FREE-LIFT CYLINDER THREE STAGE FULL FREE LIFT……………………………………………………….398
CARRIAGE THREE STAGE FULL FREE-LIFT………………………………………………………………..402
HEADER HOSE THREE STAGE FULL FREE-LIFT……………………………………………………………..404
Mast-Two Stage Full Free-Lift…………………………………………………………………………409
OUTER MAST AND MAIN LIFT TWO STAGE FULL FREE-LIFT……………………………………………………412
INNER MAST AND FREE-LIFT TWO STAGE FULL FREE-LIFT (→ 10/2013) ……………………………………….416
INNER MAST AND FREE-LIFT TWO STAGE FULL FREE-LIFT (10/2013 →) ……………………………………….420
MAIN LIFT CYLINDER TWO STAGE FULL FREE-LIFT…………………………………………………………424
FREE-LIFT CYLINDER TWO STAGE FULL FREE-LIFT…………………………………………………………428
CARRIAGE TWO STAGE FULL FREE-LIFT………………………………………………………………….432
HEADER HOSE TWO STAGE FULL FREE-LIFT……………………………………………………………….434
OPTIONS…………………………………………………………………………………………….441
ACCUMULATOR……………………………………………………………………………………..444
BACK-UP ALARM……………………………………………………………………………………446
TAIL LIGHT MOUNTING………………………………………………………………………………447
MIRRORS…………………………………………………………………………………………448
MIRROR PANORAMIC…………………………………………………………………………………449
FIRE EXTINGUISHER………………………………………………………………………………..450
REAR DRIVE HANDLE………………………………………………………………………………..451
IMPACT SENSOR……………………………………………………………………………………452
DC CONVERTER AND ATTACHING PARTS…………………………………………………………………..454
INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE LIMITED FREE LIFT CLASS III – ORFS FITTINGS ……………………..456
INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE LIMITED FREE LIFT CLASS IV – ORFS FITTINGS ………………………458
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT – 1067 MM (42 IN.) CLASS III …………………..460
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT – 1219 MM (48 IN.) CLASS III …………………..462
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT – 1219 MM (48 IN.) CLASS IV ……………………464
INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE FULL FREE-LIFT – E4.0XN ……………………………………….466
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT – 1067 MM (42 IN.) CLASS III ……………………..468
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS III ……………………..470
INTEGRAL SIDE-SHIFT THREE STAGE FULL FREE-LIFT – E4.0XN ……………………………………………..472
INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS III ……………………474
INTEGRAL SIDE-SHIFT TWO AND THREE STAGE FULL FREE-LIFT – E5.0-5.5XN/E5.0XNS ……………………………476
INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS IV ………………………478
INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT – 1219 MM (48 IN.) CLASS IV …………………….480
AUXILIARY TUBE EXTENSIONS TWO STAGE LIMITED FREE LIFT – WITHOUT QUICK DISCONNECT FITTINGS ……………….482
AUXILIARY TUBE EXTENSIONS TWO STAGE LIMITED FREE LIFT – MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ….484
AUXILIARY TUBE EXTENSIONS TWO STAGE LIMITED FREE LIFT – E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ………486
AUXILIARY TUBE EXTENSIONS THREE STAGE FULL FREE-LIFT – WITHOUT QUICK DISCONNECT FITTINGS ……………….490
AUXILIARY TUBE EXTENSIONS THREE STAGE FULL FREE-LIFT – MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ….492
AUXILIARY TUBE EXTENSIONS THREE STAGE FULL FREE-LIFT – E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ………494
AUXILIARY TUBE EXTENSIONS TWO STAGE FULL FREE-LIFT – WITHOUT QUICK DISCONNECT FITTINGS ………………….497
AUXILIARY TUBE EXTENSIONS TWO STAGE FULL FREE- LIFT – MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ……500
AUXILIARY TUBE EXTENSIONS TWO STAGE FULL FREE-LIFT – E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS …………502
FIELD SERVICE KITS…………………………………………………………………………………..505
HYDRAULIC CONVERSION KITS…………………………………………………………………………508
CONVERSION KIT ACCELERATOR PEDAL…………………………………………………………………..508
CONVERSION KIT WIDE TREAD…………………………………………………………………………508
CONVERSION KIT VERTICAL TO SIDE BATTERY REMOVAL OPTION……………………………………………….508
CONVERSION KIT FIXED TO TELESCOPE STEERING COLUMN……………………………………………………508
MISCELLANEOUS CONVERSION KITS……………………………………………………………………..509
ADD ON OPTIONS AUDIBLE ALARM………………………………………………………………………509
ADD ON OPTION KITS LIGHTS…………………………………………………………………………509
ADD ON TELEMETRY KITS…………………………………………………………………………….510
MISCELLANEOUS ADD-ON OPTION KITS…………………………………………………………………..510
NUMERICAL INDEX……………………………………………………………………………………..511
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