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C456 (12-2011) Paleteira S1.6
C456 (12-2011) Paleteira S1.6
6
(C456)
SECTIONS
1 FRAME/DRIVE UNIT
2 ELECTRICAL SYSTEM
4 LOAD WHEEL
5 HYDRAULIC SYSTEM
6 MAST-TWO STAGE
7 MAST-THREE STAGE
8 ACCESSORIES
9 NUMERICAL INDEX
This Parts Manual is divided into 9 major sections which are listed above. Quick reference to these sections can be
made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages
to the corresponding tab.
UNIT CODE C456
12/2011 EUROPE
TABLE OF CONTENTS
DESCRIPTION PAGE
B
BATTERY CHARGER
OPTION ....................................................................................................................................................... 2-6
BATTERY COMPARTMENT
INITIAL LIFT - LATERAL EXTRACTION - OPTION ................................................................................... 1-6
INITIAL LIFT - VERTICAL EXTRACTION - OPTION .................................................................................. 1-8
LATERAL EXTRACTION ............................................................................................................................ 1-4
BATTERY ROLLER TRUCK ........................................................................................................................... 8-2
C
COVERS AND ADHESIVE LABELS ............................................................................................................... 1-2
D
DRAWBAR CONTROL BOX
PROPORTIONAL SWITCH ......................................................................................................................... 1-18
E
ELECTRICAL ARRANGEMENT ..................................................................................................................... 2-2
ELECTROMAGNETIC BRAKE ....................................................................................................................... 1-16
F
FORKS CARRIAGE
MAST-THREE STAGE FULL FREE-LIFT ................................................................................................... 3-12
MAST-THREE STAGE FULL FREE-LIFT WITH INITIAL LIFT - OPTION .................................................. 3-14
MAST-TWO STAGE FULL FREE-LIFT ....................................................................................................... 3-8
MAST-TWO STAGE FULL FREE-LIFT WITH INITIAL LIFT - OPTION ...................................................... 3-10
MAST-TWO STAGE LESS FREE-LIFT ...................................................................................................... 3-4
MAST-TWO STAGE LESS FREE-LIFT WITH INITIAL LIFT - OPTION ..................................................... 3-6
H
HYDRAULIC ARRANGEMENT ....................................................................................................................... 5-2
INITIAL LIFT - OPTION ............................................................................................................................... 5-4
HYDRAULIC CYLINDER
MAST FULL FREE-LIFT ............................................................................................................................. 6-7
MAST FULL FREE-LIFT ............................................................................................................................. 7-5
MAST LESS FREE-LIFT ............................................................................................................................. 6-6
HYDRAULIC POWER PACK .......................................................................................................................... 5-6
INITIAL LIFT - OPTION ............................................................................................................................... 5-8
L
LEXAN GUARD
MAST FULL FREE-LIFT - OPTION ............................................................................................................ 6-12
MAST FULL FREE-LIFT - OPTION ............................................................................................................ 7-8
MAST LESS FREE-LIFT - OPTION ............................................................................................................ 6-10
LOAD WHEELS ............................................................................................................................................... 4-2
INITIAL LIFT - OPTION ............................................................................................................................... 4-4
M
MAST
FULL FREE-LIFT ........................................................................................................................................ 6-4
DESCRIPTION PAGE
FULL FREE-LIFT ........................................................................................................................................ 7-2
LESS FREE-LIFT ........................................................................................................................................ 6-2
P
POWER CABLES ............................................................................................................................................ 2-4
S
SUPPORTS AND CASTER WHEELS ............................................................................................................ 1-10
T
TIE RODS
INITIAL LIFT - OPTION ............................................................................................................................... 3-2
TRACTION MOTOR ........................................................................................................................................ 1-14
TRACTION UNIT ............................................................................................................................................. 1-12
W
WIRE NET ....................................................................................................................................................... 6-8
Listed below are abbreviations used in parts manuals to denote the following expressions:
spacer
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 UL Type D Diesel-Powered Safety Rating
Stacking
UL Type DS Diesel-Powered Safety Rating
ECH-5 Empty Container Handler - 5 High
Stacking UL Type E Battery-Powered Safety Rating
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.
(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, 1980, and 2003.
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.
PUBLICATIONS
Every new lift truck is provided with an OPERATING MANUALS with complete replacement part
MANUAL. This manual has information that the identification, are available at a nominal fee from your
operator must know for inspection and operation of the Hyster dealer to assist users in effectively maintaining
lift truck. Hyster lift trucks in a safe, useful condition. See the list
below for information on ordering specific publications
SERVICE MAINTENANCE MANUALS, which provide for this model lift truck.
service and overhaul procedures, and PARTS
NOTES
1 FRAME/DRIVE UNIT
UNIT CODE C456
12/2011 EUROPE
SECTION 1
FRAME/DRIVE UNIT
DESCRIPTION PAGE
BATTERY COMPARTMENT
INITIAL LIFT - LATERAL EXTRACTION - OPTION ................................................................................... 1-6
INITIAL LIFT - VERTICAL EXTRACTION - OPTION .................................................................................. 1-8
LATERAL EXTRACTION ............................................................................................................................ 1-4
COVERS AND ADHESIVE LABELS ............................................................................................................... 1-2
DRAWBAR CONTROL BOX
PROPORTIONAL SWITCH ......................................................................................................................... 1-18
ELECTROMAGNETIC BRAKE ....................................................................................................................... 1-16
SUPPORTS AND CASTER WHEELS ............................................................................................................ 1-10
TRACTION MOTOR ........................................................................................................................................ 1-14
TRACTION UNIT ............................................................................................................................................. 1-12
BATTERY COMPARTMENT
LATERAL EXTRACTION
BATTERY COMPARTMENT
INITIAL LIFT – LATERAL EXTRACTION - OPTION
BATTERY COMPARTMENT
INITIAL LIFT – VERTICAL EXTRACTION - OPTION
TRACTION UNIT
ITEM PART NO. DESCRIPTION QTY
1 292528 Capscrew ............................................................................................................ 5
2 320161 Washer ............................................................................................................... 5
3 2770500 Drive Wheel 95Sh ............................................................................................... 1
3 1491574 Drive Wheel 70Sh Rubber .................................................................................. 1
3 2770501 Drive Wheel 72Sh No marking Cold Storage ..................................................... 1
3 2770502 Drive Wheel 72Sh Gripped Cold Storage ........................................................... 1
4 1470096 Seal ................................................................................................................ 1
5 12981 Snap Ring ....................................................................................................... 1
6 67551 Snap Ring ....................................................................................................... 1
7 1470097 Shim ............................................................................................................... 1
8 1470099 Shim ............................................................................................................... 1
9 1470100 Bearing ........................................................................................................... 2
10 1470148 Kit-Gear .......................................................................................................... 1
11 1539453 Transmission Housing .................................................................................... 1
12 2794733 Key ................................................................................................................. 1
13 2793258 Key ................................................................................................................. 2
14 2792009 Bearing ........................................................................................................... 2
15 2791933 Shim ............................................................................................................... 1
16 2792105 Spacer ............................................................................................................ 1
17 1539448 Gear ............................................................................................................... 1
18 2794669 Nut .................................................................................................................. 1
19 2792314 Screw ............................................................................................................. 2
20 1470105 Bearing ........................................................................................................... 1
21 296240 Capscrew ....................................................................................................... 6
22 2792165 Screw .................................................................................................................. 3
23 296011 Capscrew ............................................................................................................ 3
24 2060217 Transmission Assy .............................................................................................. 1
25 1470106 Drain Plug ....................................................................................................... 3
26 1470108 Fitting .............................................................................................................. 2
27 2791975 Gasket ............................................................................................................ 1
28 1539449 Gear ............................................................................................................... 1
29 239503 Nut .................................................................................................................. 1
30 296418 Washer ........................................................................................................... 1
TRACTION MOTOR
ITEM PART NO. DESCRIPTION QTY
1 2106374 Electric Motor ...................................................................................................... 1
2 1700499 Terminal ......................................................................................................... 1
3 1700501 End Cover ...................................................................................................... 1
4 1470185 Bearing ........................................................................................................... 2
5 1626085 Washer ........................................................................................................... 1
6 1700507 Ring ................................................................................................................ 1
7 1700505 Wheel ............................................................................................................. 1
8 1700503 Support Plate .................................................................................................. 1
9 1700504 Spacer ............................................................................................................ 1
10 1700502
4012949 Sensor ............................................................................................................ 1
11 1701031 Oil Seal ........................................................................................................... 1
12 12929 Snap Ring ....................................................................................................... 1
13 12928 Snap Ring ....................................................................................................... 1
14 1700500 End Cover ...................................................................................................... 1
15 1700498 Stator .............................................................................................................. 1
16 1700506 Rotor ............................................................................................................... 1
17 1366857 Stud ................................................................................................................ 6
18 388048 Disk ................................................................................................................ 3
ELECTROMAGNETIC BRAKE
ITEM PART NO. DESCRIPTION QTY
1 1657716 Brake Assy .......................................................................................................... 1
2 296002 Capscrew ....................................................................................................... 3
3 1657715 Coil ................................................................................................................. 1
4 1524570 Coil (Hub) ....................................................................................................... 1
5 2792087 Disk ................................................................................................................ 1
6 1646927 Disk ................................................................................................................ 1
7 2045943 Band ................................................................................................................... 1
8 2069533 Dust Cap ............................................................................................................. 1
NOTES
2 ELECTRICAL SYSTEM
UNIT CODE C456
12/2011 EUROPE
SECTION 2
ELECTRICAL SYSTEM
DESCRIPTION PAGE
BATTERY CHARGER
OPTION ....................................................................................................................................................... 2-6
ELECTRICAL ARRANGEMENT ..................................................................................................................... 2-2
POWER CABLES ............................................................................................................................................ 2-4
ELECTRICAL ARRANGEMENT
ITEM PART NO. DESCRIPTION QTY
1 ab 2039023 Sensor ................................................................................................................ 2
2 ab 2794114 Support ............................................................................................................... 1
3 ab 320154 Washer ............................................................................................................... 2
4 ab 293727 Capscrew ............................................................................................................ 2
5 b 1707673 Display (MDI) ...................................................................................................... 1
6 2770368 Adhesive ............................................................................................................. 1
7 1693742 Switch ................................................................................................................. 1
8 2790487 BDI And Hourmeter ............................................................................................ 1
9 1694069 Cover .................................................................................................................. 1
10 296509 Screw .................................................................................................................. 2
11 320155 Washer ............................................................................................................... 5
12 4038296 Ignition Switch ..................................................................................................... 1
13 4041497 Key ................................................................................................................. 1
14 339530 Clamp ................................................................................................................. 2
15 1594442 Isolator ................................................................................................................ 1
16 239503 Nut ...................................................................................................................... 4
17 320157 Washer ............................................................................................................... 6
18 293742 Screw .................................................................................................................. 2
19 1648884 Fuse (300 Amp) .................................................................................................. 1
20 2108634 Controller ............................................................................................................ 1
21 1588252 Support ............................................................................................................... 1
22 296153 Capscrew ............................................................................................................ 2
23 1337828 Fuse (3 Amp) ...................................................................................................... 2
24 370646 Fuse (5 Amp) ...................................................................................................... 1
25 370647 Fuse (10 Amp) .................................................................................................... 1
26 1590162 Fuse Holder (5 Amp) .......................................................................................... 3
27 1589277 Fuse Holder (10 Amp) ........................................................................................ 1
28 302398 Locknut ............................................................................................................... 3
29 1512440
302399 Nut ...................................................................................................................... 7
30 320156 Washer ............................................................................................................... 12
31 2770378 Shock Absorber .................................................................................................. 2
32 1692941 Relay ................................................................................................................... 1
33 1692973 Horn .................................................................................................................... 1
34 292500 Capscrew ............................................................................................................ 1
35 292501 Capscrew ............................................................................................................ 2
36 b 2111349 Wire Harness (MDI) ............................................................................................ 1
37 ab 4600950 Wire Harness (Sensors) ..................................................................................... 1
38 2108354 Wire Harness ...................................................................................................... 1
38 ab 4600948 Wire Harness ...................................................................................................... 1
FOOTNOTES:
a Only for Initial Lift version b OPTION
FOOTNOTES:
a Only for initail lift version (OPTION)
NOTES
BATTERY CHARGER
OPTION
NOTES
SECTION 3
LIFT LINKAGE AND FORKS
DESCRIPTION PAGE
FORKS CARRIAGE
MAST-THREE STAGE FULL FREE-LIFT ................................................................................................... 3-12
MAST-THREE STAGE FULL FREE-LIFT WITH INITIAL LIFT - OPTION .................................................. 3-14
MAST-TWO STAGE FULL FREE-LIFT ....................................................................................................... 3-8
MAST-TWO STAGE FULL FREE-LIFT WITH INITIAL LIFT - OPTION ...................................................... 3-10
MAST-TWO STAGE LESS FREE-LIFT ...................................................................................................... 3-4
MAST-TWO STAGE LESS FREE-LIFT WITH INITIAL LIFT - OPTION ..................................................... 3-6
TIE RODS
INITIAL LIFT - OPTION ............................................................................................................................... 3-2
TIE RODS
INITIAL LIFT – OPTION
NOTES
FORKS CARRIAGE
MAST-TWO STAGE LESS FREE-LIFT WITH INITIAL LIFT – OPTION
NOTES
FORKS CARRIAGE
MAST-TWO STAGE FULL FREE-LIFT WITH INITIAL LIFT – OPTION
NOTES
FORKS CARRIAGE
MAST-THREE STAGE FULL FREE-LIFT WITH INITIAL LIFT – OPTION
NOTES
4 LOAD WHEEL
UNIT CODE C456
12/2011 EUROPE
SECTION 4
LOAD WHEEL
DESCRIPTION PAGE
LOAD WHEELS
ITEM PART NO. DESCRIPTION QTY
1 1531786 Roller .................................................................................................................. 2
2 1530189 Bushing .......................................................................................................... 2
3 3041219 Seal ................................................................................................................ 2
4 1531790 Roller .............................................................................................................. 1
5 194723 Ball Bearing .................................................................................................... 2
6 1531789 Roller .............................................................................................................. 1
7 302452 Roll Pin ........................................................................................................... 6
8 2770370 Pin ....................................................................................................................... 2
9 2791942 Grease Fitting ..................................................................................................... 2
10 2770656 Rocker Arm ......................................................................................................... 2
11 2791931 Washer ............................................................................................................... 8
12 1530205 Roller .............................................................................................................. 1
13 1531787 Roller .............................................................................................................. 1
14 1531785 Roller .................................................................................................................. 4
15 2781515 Plate .................................................................................................................... 2
16 2781516 Pin ....................................................................................................................... 4
17 2793240 Bushing ............................................................................................................... 4
18 2790462 Grease Fitting ..................................................................................................... 4
19 296252 Capscrew ............................................................................................................ 4
20 1530185 Roller .................................................................................................................. 4
21 2781514 Plate .................................................................................................................... 2
22 1531788 Roller .................................................................................................................. 2
23 2792265 Pin ....................................................................................................................... 4
24 302456 Roll Pin ............................................................................................................... 2
25 1530204 Roller .................................................................................................................. 1
LOAD WHEELS
INITIAL LIFT – OPTION
NOTES
5 HYDRAULIC SYSTEM
UNIT CODE C456
12/2011 EUROPE
SECTION 5
HYDRAULIC SYSTEM
DESCRIPTION PAGE
HYDRAULIC ARRANGEMENT
KEY:
A: 2 STG Hi Vi
B: 2 STG FFL
C: 3 STG FFL
QTY
ITEM PART NO. DESCRIPTION A B C
1 2798663 Fitting ................................................................................................. 2 2 3
2 2798661 Fitting ................................................................................................. 2 2 1
3 2770396 Hydraulic Tube .................................................................................. 1 1 1
4 2770686 Tube Assy ......................................................................................... 1 1 1
5 14560 Fitting ................................................................................................. .. .. 1
6 2770690 Tube .................................................................................................. .. .. 1
7 16447 Fitting ................................................................................................. .. .. 2
8 2770680 Hose h=4025mm ............................................................................... .. .. 1
8 2770682 Hose h=4325mm ............................................................................... .. .. 1
8 a 2770681 Hose h=4625mm ............................................................................... .. .. 1
8 a 1482602 Hose h=4795mm ............................................................................... .. .. 1
8 a 1482606 Hose h=5095mm ............................................................................... .. .. 1
8 a 1482608 Hose h=5395mm ............................................................................... .. .. 1
9 17319 Fitting ................................................................................................. .. .. 1
10 17218 Fitting ................................................................................................. .. .. 1
11 2770687 Tube h=4025mm ............................................................................... .. .. 1
11 2770688 Tube h=4325mm ............................................................................... .. .. 1
11 a 2770689 Tube h=4625mm ............................................................................... .. .. 1
11 a 1482585 Tube h=4795mm ............................................................................... .. .. 1
11 a 1482586 Tube h=5095mm ............................................................................... .. .. 1
11 a 1482587 Tube h=5395mm ............................................................................... .. .. 1
12 1501136 Seal ................................................................................................... .. 2 ..
13 2796401 Hose Failure Valve Body ................................................................... .. 2 ..
14 2046591 Hyd Pipe Ftg ...................................................................................... .. 2 ..
15 2780095 Fitting ................................................................................................. .. 2 ..
16 1499004 Tube Assy ......................................................................................... .. 1 ..
17 1499006 Tube Assy h=2603mm ...................................................................... .. 1 ..
17 1499009 Tube Assy h=2803mm ...................................................................... .. 1 ..
17 1499011 Tube Assy h=3003mm ...................................................................... .. 1 ..
17 1499013 Tube Assy h=3203mm ...................................................................... .. 1 ..
17 1499014 Tube Assy h=3403mm ...................................................................... .. 1 ..
17 1499015 Tube Assy h=3603mm ...................................................................... .. 1 ..
17 1499016 Tube Assy h=4003mm ...................................................................... .. 1 ..
FOOTNOTES:
a only for 1,6ton
HYDRAULIC ARRANGEMENT
INITIAL LIFT – OPTION
NOTES
6 MAST-TWO STAGE
UNIT CODE C456
12/2011 EUROPE
SECTION 6
MAST-TWO STAGE
DESCRIPTION PAGE
HYDRAULIC CYLINDER
MAST FULL FREE-LIFT ............................................................................................................................. 6-7
MAST LESS FREE-LIFT ............................................................................................................................. 6-6
LEXAN GUARD
MAST FULL FREE-LIFT - OPTION ............................................................................................................ 6-12
MAST LESS FREE-LIFT - OPTION ............................................................................................................ 6-10
MAST
FULL FREE-LIFT ........................................................................................................................................ 6-4
LESS FREE-LIFT ........................................................................................................................................ 6-2
WIRE NET ....................................................................................................................................................... 6-8
MAST
LESS FREE-LIFT
MAST
FULL FREE-LIFT
WIRE NET
ITEM PART NO. DESCRIPTION QTY
1 2770442 Guard h3=1275mm ............................................................................................. 1
1 2770443 Guard h3=1375mm ............................................................................................. 1
1 2770444 Guard h3=1475-1575-1775mm .......................................................................... 1
1 2770369 Guard h3=2830mm ............................................................................................. 1
1 2770441 Guard h3=3030mm ............................................................................................. 1
1 2770442 Guard h3=3230mm ............................................................................................. 1
1 2770443 Guard h3=3430mm ............................................................................................. 1
1 2770444 Guard h3=3830mm ............................................................................................. 1
2 2792005 Clip ...................................................................................................................... 6
3 2794227 Nut ...................................................................................................................... 6
4 2770652 Screw .................................................................................................................. 6
LEXAN GUARD
MAST LESS FREE-LIFT – OPTION
LEXAN GUARD
MAST FULL FREE-LIFT – OPTION
NOTES
7 MAST-THREE STAGE
UNIT CODE C456
12/2011 EUROPE
SECTION 7
MAST-THREE STAGE
DESCRIPTION PAGE
HYDRAULIC CYLINDER
MAST FULL FREE-LIFT ............................................................................................................................. 7-5
LEXAN GUARD
MAST FULL FREE-LIFT - OPTION ............................................................................................................ 7-8
MAST
FULL FREE-LIFT ........................................................................................................................................ 7-2
WIRE NET ....................................................................................................................................................... 7-6
MAST
FULL FREE-LIFT
MAST
FULL FREE-LIFT
FOOTNOTES:
a only for 1,6ton
FOOTNOTES:
a only for 1,6ton
WIRE NET
ITEM PART NO. DESCRIPTION QTY
1 2770369 Guard h=4025mm ............................................................................................... 1
1 2770441 Guard h=4325mm ............................................................................................... 1
1 a 2770442 Guard h=4625mm ............................................................................................... 1
1 a 1477510 Guard h=4795mm ............................................................................................... 1
1 a 1482415 Guard h=5095mm ............................................................................................... 1
1 a 1482416 Guard h=5395mm ............................................................................................... 1
2 2792005 Clip ...................................................................................................................... 6
3 2794227 Nut ...................................................................................................................... 6
4 2770652 Screw .................................................................................................................. 6
FOOTNOTES:
a only for 1,6ton
LEXAN GUARD
MAST FULL FREE-LIFT – OPTION
FOOTNOTES:
a only for 1,6t
NOTES
8 ACCESSORIES
UNIT CODE C456
12/2011 EUROPE
SECTION 8
ACCESSORIES
DESCRIPTION PAGE
9 NUMERICAL INDEX
UNIT CODE C456
12/2011 EUROPE
SECTION 9
NUMERICAL INDEX
PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM PART NO. PAGE ITEM