CUSTOMER EDITION
PARTS
MANUAL
E3.50XL, E4.00XL,
E4.50XL/XLS, E5.50XL
(D098)
1596590 ©2005 Hyster Company
10/2005
10/2005
UNIT CODE D098
EUROPE
SECTIONS
1 FRAME
2 ELECTRICAL SYSTEM
3 DRIVE UNIT
4 STEERING SYSTEM
5 BRAKE/ACCELERATOR SYSTEM
6 HYDRAULIC SYSTEM
7 MAST-TWO STAGE LIMITED FREE-LIFT
8 MAST-THREE STAGE FULL FREE-LIFT
9 MAST-TWO STAGE FULL FREE-LIFT
10 OPTIONS
11 NUMERICAL INDEX
This Parts Manual is divided into 11 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the
pages to the corresponding tab.
10/2005
UNIT CODE D098
EUROPE
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCELERATOR ASSEMBLY ............................................................................................................................. 5-14
ACCUMULATOR ................................................................................................................................................ 10-2
B
BATTERY SPACER .............................................................................................................................................. 1-4
BRAKE ASSEMBLY ............................................................................................................................................. 5-6
BRAKE LINKAGE ................................................................................................................................................. 5-4
BRAKE RELAY ASSEMBLY ............................................................................................................................... 5-12
C
CARRIAGE
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-24
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-18
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-14
CONTACTOR
POWER STEERING ON-DEMAND ................................................................................................................ 2-12
CONTACTOR PANEL ......................................................................................................................................... 2-10
CONTROL PANEL
36/48 VOLT ....................................................................................................................................................... 2-6
72/80 VOLT ....................................................................................................................................................... 2-8
CONTROL VALVE
FOUR FUNCTION .......................................................................................................................................... 6-20
THREE FUNCTION ........................................................................................................................................ 6-16
COUNTERWEIGHT ........................................................................................................................................... 1-20
D
DC-DC CONVERTER
36/48 VOLT TO 12 VOLT
70/80 VOLT TO 12 VOLT ........................................................................................................................... 10-10
DRIVE AXLE ........................................................................................................................................................ 3-4
DRIVE LIGHTS................................................................................................................................................... 10-4
DRIVE TIRE AND WHEEL ................................................................................................................................... 3-2
E
ELECTRICAL SYSTEM........................................................................................................................................ 2-2
F
FLOOR PLATES AND COVERS .......................................................................................................................... 1-2
FORKS
CLASS III ....................................................................................................................................................... 1-24
OPTIONAL .................................................................................................................................................. 1-25
CLASS IV........................................................................................................................................................ 1-28
OPTIONAL .................................................................................................................................................. 1-29
FREE-LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-12
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-14
FREE-LIFT CYLINDERS
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-20
FULL SUSPENSION SEAT
©2005 HYSTER COMPANY i
See Service Manual
for service procedures.
UNIT CODE D098
EUROPE 10/2005
TABLE OF CONTENTS (Continued)
DESCRIPTION PAGE
F (continued)
SHEET 1 OF 2 ................................................................................................................................................ 1-14
SHEET 2 OF 2 ................................................................................................................................................ 1-16
G
GEAR PUMP ...................................................................................................................................................... 4-12
H
HAND LEVERS .................................................................................................................................................. 6-14
HEADER HOSE
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-20
MAST HEIGHTS 2790 AND 3050 MM........................................................................................................ 9-22
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-16
MAST HEIGHTS 2790MM AND 3050MM................................................................................................... 7-20
HEADER HOSES
THREE STAGE FULL FREE-LIFT
HEIGHTS 4940 AND 5200 MM AND ABOVE ............................................................................................. 8-30
HEIGHTS LESS THAN 4940 AND 5200 MM.............................................................................................. 8-26
HOOD................................................................................................................................................................... 1-6
HYDRAULIC
SINGLE PUMP AND MOTOR........................................................................................................................... 6-2
HYDRAULIC FILTER .......................................................................................................................................... 6-12
HYDRAULIC MOTOR ......................................................................................................................................... 6-10
HYDRAULIC PLUMBING
CONTROL VALVE ............................................................................................................................................ 6-6
HYDRAULIC PUMP
29 CC................................................................................................................................................................ 6-8
HYDRAULIC SUPPLY AND RETURN.................................................................................................................. 6-4
I
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-6
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-4
INNER MAST AND FREE-LIFT
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-6
INTEGRAL SIDE-SHIFT
THREE STAGE FULL FREE-LIFT
E3.50-4.00XL, E4.50XLS .......................................................................................................................... 10-20
E4.50-5.50XL ............................................................................................................................................ 10-22
TWO STAGE FULL FREE-LIFT
E3.50XL, E4.00XL, E4.50XLS................................................................................................................... 10-16
E4.50-5.50XL ............................................................................................................................................ 10-18
TWO STAGE LIMITED FREE-LIFT
E3.50XL, E4.00XL, E4.50XLS................................................................................................................... 10-12
E4.50-E5.50XL .......................................................................................................................................... 10-14
INTEGRAL SIDE-SHIFT CARRIAGE
THREE STAGE FULL FREE-LIFT
1067 MM (42 IN.) CLASS III...................................................................................................................... 10-36
1219 MM (48 IN.) CLASS III...................................................................................................................... 10-38
1219 MM (48 IN.) CLASS IV ..................................................................................................................... 10-40
ii ©2005 HYSTER COMPANY
See Service Manual
for service procedures.
10/2005
UNIT CODE D098
EUROPE
TABLE OF CONTENTS (Continued)
DESCRIPTION PAGE
I (continued)
TWO STAGE FULL FREE-LIFT
1067 MM (42 IN.) CLASS III...................................................................................................................... 10-30
1219 MM (48 IN.) CLASS III...................................................................................................................... 10-32
1219 MM (48 IN.) CLASS IV ..................................................................................................................... 10-34
TWO STAGE LIMITED FREE-LIFT
1067 MM (42 IN.) CLASS III...................................................................................................................... 10-24
1219 MM (48 IN.) CLASS III...................................................................................................................... 10-26
1219 MM (48 IN.) CLASS IV ..................................................................................................................... 10-28
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-4
L
LABELS ................................................................................................................................................................ 1-8
LED BACK-UP AND BRAKE LIGHTS ................................................................................................................ 10-6
LINE CONTACTOR ............................................................................................................................................ 2-14
LOAD BACKREST EXTENSIONS ..................................................................................................................... 1-22
M
MAIN LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-8
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6
MAIN LIFT CYLINDER
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-10
TWO STAGE LIMITED FREE-LIFT
E3.50-4.00XL, E4.50XLS ............................................................................................................................ 7-10
E4.50-5.50XL .............................................................................................................................................. 7-12
MAIN LIFT CYLINDERS
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-16
MAST INSTALLATION ........................................................................................................................................ 6-24
MASTER CYLINDER ......................................................................................................................................... 5-10
MONOTROL PEDAL .......................................................................................................................................... 5-16
N
NON SUSPENSION SEAT ................................................................................................................................. 1-12
O
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-2
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-2
OUTER MAST AND MAIN LIFT
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-2
OVERHEAD GUARD
WITH CURVED LEG....................................................................................................................................... 1-18
WITH STRAIGHT LEG ................................................................................................................................... 1-26
©2005 HYSTER COMPANY iii
See Service Manual
for service procedures.
UNIT CODE D098
EUROPE 10/2005
TABLE OF CONTENTS (Continued)
DESCRIPTION PAGE
P
PARK BRAKE
LEVER ACTUATED .......................................................................................................................................... 5-2
S
SEMI SUSPENSION SEAT
WITH ARM REST ........................................................................................................................................... 1-10
SHIFT LEVER .................................................................................................................................................... 4-16
STEER AXLE ASSEMBLY ................................................................................................................................... 4-2
STEER TIRE AND WHEEL .................................................................................................................................. 4-8
STEERING COLUMN......................................................................................................................................... 4-14
STEERING CYLINDER ........................................................................................................................................ 4-6
STEERING MOTOR AND PUMP ....................................................................................................................... 4-10
STEERING PUMP .............................................................................................................................................. 4-18
STROBE LIGHT ................................................................................................................................................. 10-8
T
TILT CYLINDER ................................................................................................................................................. 6-26
TRACTION MOTOR ........................................................................................................................................... 3-12
TRANSMISSION ASSEMBLY .............................................................................................................................. 3-8
W
WIRE HARNESS
BRAKE SWITCH............................................................................................................................................. 2-30
DASH DISPLAY ................................................................................................................................................ 2-5
LIGHTS ........................................................................................................................................................... 2-28
MAIN CONTROL
SHEET 1 0F 2
S/N D098N01717C⇒ .............................................................................................................................. 2-20
⇒S/N D098N01717C .............................................................................................................................. 2-16
SHEET 2 OF 2
⇒S/N D098N01717C .............................................................................................................................. 2-18
S/N D098N01718C⇒ .............................................................................................................................. 2-22
WIRE HARNESS (MAIN CONTROL)
80 VOLT
SHEET 1 OF 2 ............................................................................................................................................ 2-24
SHEET 2 OF 2 ............................................................................................................................................ 2-26
iv ©2005 HYSTER COMPANY
See Service Manual
for service procedures.
10/2005
UNIT CODE D098
EUROPE
ABBREVIATIONS QUICK REFERENCE SHEET
Listed below are abbreviations used in parts manuals to denote the following expressions:
TERM DEFINITION
Amp Amperes
AR As Required
BDI Battery Discharge Indicators
BWI Brush Wear Indicator
CE Communicator End
CRE Corrosive Environment
D/B Date Break
dbA Decibel "A" Scale
DE Drive End
ECH Empty Container Handler
ECH-3 Empty Container Handler - 3 High
Stacking
ECH-4 Empty Container Handler - 4 High
Stacking
ECH-5 Empty Container Handler - 5 High
Stacking
ECH-6 Empty Container Handler - 6 High
Stacking
ECH-7 Empty Container Handler - 7 High
Stacking
ECM Electronic Control Module
ECN Engineering Change Notice
EEPROM Electrically Erasable Programmable
Read Only Memory
EPA US Environmental Protection Agency
EPROM Electrically Programmable Read Only
Memory
TERM DEFINITION
FRE Freezer Environment
in. inches
LPG Liquefied Petroleum Gas
MAP Manifold Absolute Pressure
mm
millimeters
MSTS Microprocessor Spark Timing System
NPT National Pipe Threads
O/S Oversize
PTO Power Take Off
RPM Revolutions per Minute
S/N Serial Number
TMM Truck Management Module
UL Type D Diesel-Powered Safety Rating
UL Type DS Diesel-Powered Safety Rating
UL Type E Battery-Powered Safety Rating
UL Type EE Battery-Powered Safety Rating
UL Type ES Battery-Powered Safety Rating
UL Type G Gasoline-Powered Safety Rating
UL Type GS Gasoline-Powered Safety Rating
UL Type LP Gas-Powered Safety Rating
UL Type LPS LP Gas-Powered Safety Rating
U/S Undersize
UL Underwriters Laboratory
V Volts
©2005 HYSTER COMPANY v
See Service Manual
for service procedures.
UNIT CODE D098
EUROPE 10/2005
HOW TO USE THE ILLUSTRATED PARTS MANUAL
This parts manual describes and illustrates assemblies,
subassemblies, and detail parts needed for service
replacement.
The different constructions are indicated by keys and
footnotes. The callouts correspond to descriptions
found on the next page.
vi ©2005 HYSTER COMPANY
See Service Manual
for service procedures.
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Hyster D098 (E3.50XL, E4.00XL, E4.50XL/XLS, E5.50XL) Forklift Parts Manual
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What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
The Hyster D098 (E3.50XL, E4.00XL, E4.50XL/XLS, E5.50XL) Forklift Parts Manual is a comprehensive resource designed to provide all the necessary information for the maintenance and repair of the forklift. It contains easy-to-understand text sections accompanied by high-quality diagrams and instructions, making it valuable for both professional mechanics and DIY enthusiasts.
Key areas covered in this manual include:
- Frame
- Electrical System
- Drive Unit
- Steering System
- Brake / Accelerator System
- Hydraulic System
- Mast-Two Stage Limited Free-Lift
- Mast-Three Stage Full Free-Lift
- Mast-Two Stage Full Free-Lift
- Options
- Numerical Index
The manual is available in PDF format, compatible with all versions of Windows and Mac. It is presented in English and requires Adobe Reader for access. This Parts Manual is an essential tool for anyone working with the Hyster D098 (E3.50XL, E4.00XL, E4.50XL/XLS, E5.50XL) Forklift, offering the necessary insights to efficiently carry out maintenance and repairs, ultimately saving time and money.
Having the right Parts Manual for your forklift is crucial, and this manual provides the detailed information needed to understand and maintain the Hyster D098 (E3.50XL, E4.00XL, E4.50XL/XLS, E5.50XL) Forklift. Additionally, all pages are printable, adding to the convenience and accessibility of the manual.
