Hyster R005 (H80FT, H90FT, H100FT, H110FT, H120FT) Forklift Parts Manual

H80-H120FT (R005)

4047190 10/2015

©2015 HYSTER COMPANY

UNIT CODE R005 NORTH AMERICA

10/2015

SECTIONS 1

FRAME

2

ENGINE ASSEMBLY - DIESEL

3

ENGINE ASSEMBLY - GM

4

FUEL SYSTEM

5

ELECTRICAL SYSTEM

6

TRANSMISSION

7

DRIVE AXLE

8

STEERING SYSTEM

9

BRAKE SYSTEM

10

HYDRAULIC SYSTEM

11

MAST-TWO STAGE LIMITED FREE-LIFT

12

MAST-TWO STAGE FULL FREE-LIFT

13

MAST-THREE STAGE FULL FREE-LIFT

14

OPTIONS

15

FIELD CONVERSION KITS

16

NUMERICAL INDEX

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UNIT CODE R005 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

A ACCUMULATOR .............................................................................................................................................

ADD ON TELEMETRY KITS ...........................................................................................................................

ADD-ON OPTION KITS ...................................................................................................................................

AIR FILTER .....................................................................................................................................................

AIR INTAKE KUBOTA DIESEL ........................................................................................................................................

AIR INTAKE AND FILTER SYSTEM GM 4.3L, GASOLINE AND LPG - PSI ........................................................................................................

ALTERNATOR SEALED - KUBOTA 3.8L DIESEL ..............................................................................................................

SEALED - GM 4.3L GASOLINE AND LPG .................................................................................................

ALTERNATOR AND MOUNTING GM 4.3L GASOLINE AND LPG - PSI OPTION ...........................................................................................

ALTERNATOR AND PULLEY KUBOTA DIESEL ........................................................................................................................................

ARMREST ASSEMBLY MINI-LEVER MODULES - (SEMI-SUSPENSION SEAT WITH LH HIP RESTRAINT) ...............................

MINI-LEVER MODULES .............................................................................................................................

AUXILIARY HOSES ........................................................................................................................................

B BACK-UP ALARM ...........................................................................................................................................

BAFFLE AND ATTACHING PARTS KUBOTA DIESEL - LONG WHEEL BASE ..................................................................................................

BATTERY CABLE FUSED - KUBOTA 3.6L DIESEL ................................................................................................................

BATTERY CABLES GM 4.3L GASOLINE AND LPG - PSI OPTION ...........................................................................................

KUBOTA DIESEL ........................................................................................................................................

BATTERY DISCONNECT GM 4.3L GASOLINE AND LPG - PSI OPTION ...........................................................................................

KUBOTA 3.8L DIESEL ................................................................................................................................

BRAKE ASSEMBLY DRY BRAKE ................................................................................................................................................

BRAKE COOLING SYSTEM SINGLE AND DUAL PEDAL - WET BRAKE ...............................................................................................

BRAKE LINKAGE DUAL PEDAL - DRY BRAKE ......................................................................................................................

DUAL PEDAL (WET BRAKE) - EARLY PRODUCTION .............................................................................

DUAL PEDAL (WET BRAKE) - LATE PRODUCTION ................................................................................

SINGLE PEDAL - DRY BRAKE ..................................................................................................................

SINGLE PEDAL (WET BRAKE) - EARLY PRODUCTION ..........................................................................

SINGLE PEDAL (WET BRAKE) - LATE PRODUCTION ............................................................................

BRAKE MASTER CYLINDER ASSEMBLY .....................................................................................................

BREATHER AND SEPARATOR PIPES KUBOTA DIESEL - (3.8L) ...........................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

14-60 15-9 15-7 4-4 4-6 4-2 5-43 5-45 5-44 2-84 1-34 1-36 10-52 14-58 2-92 5-14 5-16 5-12 5-20 5-18 9-24 9-26 9-20 9-8 9-12 9-16 9-2 9-6 9-32 2-72

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PAGE

C CAB ASSEMBLY WITH STEEL DOORS FAN ASSEMBLY .........................................................................................................................................

HEADLINER ASSEMBLY ...........................................................................................................................

WINDOWS AND WIPERS - ADHESIVE SEALED FRONT WINDOW ........................................................

WITH AIR CONDITIONING - SHEET 1 OF 3 .............................................................................................

WITH AIR CONDITIONING - SHEET 2 OF 3 .............................................................................................

WITH AIR CONDITIONING - SHEET 3 OF 3 .............................................................................................

WITH AIR CONDITIONING - WINDOWS AND WIPERS-ADHESIVE SEALED FRONT WINDOW ...........

WITH AIR CONDITIONING - LEFT HAND DOOR ......................................................................................

WITH AIR CONDITIONING - RIGHT HAND DOOR LATCH COMPONENTS ............................................

WITH AIR CONDITIONING - RIGHT HAND DOOR HEATER COMPONENTS .........................................

WITH AIR CONDITIONING - CONDENSER AND ATTACHING PARTS (SHEET 1 OF 2) ........................

WITH AIR CONDITIONING - DRYER AND ATTACHING PARTS (SHEET 2 OF 2) ..................................

WITH AIR CONDITIONING - HEATER COMPONENTS ............................................................................

WITHOUT AIR CONDITIONING - SHEET 1 OF 3 ......................................................................................

WITHOUT AIR CONDITIONING - SHEET 2 OF 3 ......................................................................................

WITHOUT AIR CONDITIONING - SHEET 3 OF 3 ......................................................................................

WITHOUT AIR CONDITIONING - LEFT HAND DOOR ..............................................................................

WITHOUT AIR CONDITIONING - RIGHT HAND DOOR LATCH COMPONENTS ....................................

WITHOUT AIR CONDITIONING - RIGHT HAND DOOR HEATER COMPONENTS .................................

CAMSHAFT AND IDLE GEAR SHAFT KUBOTA DIESEL - (3.6L, 3.8L) ..................................................................................................................

CAMSHAFT AND OIL PAN GM 4.3L GASOLINE AND LPG - PSI .........................................................................................................

CARRIAGE LOCKOUT ROD CARRIER ASSEMBLY DRY BRAKE ................................................................................................................................................

COMPRESSOR ASSEMBLY KUBOTA DIESEL - (3.8L) ...........................................................................................................................

CONDENSER ASSEMBLY .............................................................................................................................

CONTROL MODULE DIESEL INTERFACE - KUBOTA V3800 .....................................................................................................

CONTROL VALVE ASSEMBLY ELECTRONIC CONTROL - THREE FUNCTION ........................................................................................

ELECTRONIC CONTROL - FOUR FUNCTION ..........................................................................................

MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ...............................................................

CONTROL VALVE LOCKOUT GROUP MANUAL CONTROL VALVE ......................................................................................................................

COOLANT HOSES GM 4.3L LPG WITH CAB - PSI ...................................................................................................................

COOLING GASOLINE AND LPG - WITH EXTERNAL OIL COOLER ..........................................................................

GASOLINE AND LPG - WITH INTERNAL OIL COOLER ...........................................................................

KUBOTA DIESEL - WITH EXTERNAL OIL COOLER ................................................................................

KUBOTA DIESEL - WITHOUT EXTERNAL OIL COOLER .........................................................................

COUNTERWEIGHT ........................................................................................................................................

COVER BEARING CASE KUBOTA DIESEL - 3.6L, 3.8L .....................................................................................................................

ii

See Service Manual for service procedures.

1-94 1-96 1-64 1-72 1-74 1-76 1-78 1-80 1-82 1-84 1-86 1-88 1-92 1-58 1-60 1-62 1-66 1-68 1-70 2-80 3-34 7-10 2-22 1-90 5-30 10-28 10-30 10-18 10-20 4-21 3-4 3-6 2-14 2-16 1-14 2-82

©2015 HYSTER COMPANY

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TABLE OF CONTENTS (continued) DESCRIPTION

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COWL ELECTRICAL ELECTRO-HYDRAULICS ...........................................................................................................................

MANUAL HYDRAULICS .............................................................................................................................

COWL MOUNT ................................................................................................................................................

CRANKSHAFT PULLEY GM 4.3L GASOLINE AND LPG - PSI .........................................................................................................

CYLINDER BLOCK GM 4.3L GASOLINE AND LPG - PSI .........................................................................................................

KUBOTA DIESEL - (3.6L, 3.8L) ..................................................................................................................

CYLINDER HEAD GM 4.3L GASOLINE AND LPG - PSI .........................................................................................................

KUBOTA DIESEL - (3.6L) ...........................................................................................................................

KUBOTA DIESEL - (3.8L) ...........................................................................................................................

CYLINDER HEAD COVER KUBOTA DIESEL - (3.6L) ...........................................................................................................................

KUBOTA DIESEL - (3.8L) ...........................................................................................................................

D DIFFERENTIAL DRY BRAKE ................................................................................................................................................

WET BRAKE ...............................................................................................................................................

DIFFERENTIAL ASSEMBLY WET BRAKE (NMHG) .................................................................................................................................

DIPSTICK KUBOTA DIESEL - (3.6L, 3.8L) ..................................................................................................................

DIRECTIONAL CONTROL ..............................................................................................................................

DISTRIBUTER AND COIL GM 4.3L GASOLINE AND LPG - PSI .........................................................................................................

DISTRIBUTOR ASSEMBLY GM 4.3L LPG AND GASOLINE ..................................................................................................................

DRIVE AXLE AND ATTACHING PARTS DRY BRAKE ................................................................................................................................................

WET BRAKE ...............................................................................................................................................

DRIVE AXLE ASSEMBLY DRY BRAKE ................................................................................................................................................

WET BRAKE (NMHG) - RIGHT AND LEFT HAND HUBS ..........................................................................

WET BRAKE (NMHG) - BRAKES AND DIFFERENTIAL ............................................................................

WET BRAKE (NMHG) - INPUT PINION CARRIER ....................................................................................

DRIVE AXLE HOUSING AND HUB WET BRAKE ...............................................................................................................................................

DRIVE WHEELS AND TIRES DUAL TREAD ..............................................................................................................................................

SINGLE TREAD ..........................................................................................................................................

DUAL MIRRORS WITH CAB ...................................................................................................................................................

5-24 5-22 1-12 3-26 3-32 2-28 3-30 2-35 2-36 2-33 2-34

7-8 7-16 7-28 2-32 15-6 3-42 5-36 7-2 7-12 7-4 7-22 7-24 7-26 7-14 7-34 7-32 14-55

E EGR VALVE AND COOLER KUBOTA DIESEL - (3.8L) ........................................................................................................................... 2-68

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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EGR VALVE FLANGE KUBOTA DIESEL - (3.8L) ...........................................................................................................................

ELECTRICAL MOUNTING PLATE AND LIFTING EYE GM 4.3L GASOLINE - PSI OPTION ...........................................................................................................

GM 4.3L LPG - PSI .....................................................................................................................................

ELECTRICAL SYSTEM RIGHT HAND CHASSIS .............................................................................................................................

ELECTRO HYDRAULIC POPPET VALVE THREE AND FOUR FUNCTION .................................................................................................................

ENGINE CONTROL MODULE AND SENSORS GM 4.3L LPG - PSI OPTION .......................................................................................................................

GM 4.3L GASOLINE - PSI OPTION ...........................................................................................................

ENGINE ELECTRICAL SYSTEM GM 4.3L GASOLINE AND LPG - "E" CONSTRUCTION ............................................................................

KUBOTA 3.6L DIESEL ................................................................................................................................

KUBOTA 3.8L DIESEL ................................................................................................................................

ENGINE HARNESS MOUNTING - KUBOTA 3.6L DIESEL .........................................................................................................

ENGINE MOUNTING GM 4.3L, GASOLINE AND LPG .................................................................................................................

ENGINE WITH ENGINE MOUNT AND TORQUE CONVERTER KUBOTA DIESEL ........................................................................................................................................

EXHAUST MANIFOLD KUBOTA DIESEL - (3.6L) ...........................................................................................................................

KUBOTA DIESEL - (3.8L) ...........................................................................................................................

EXHAUST MANIFOLDS GM 4.3L LPG AND GASOLINE - PSI OPTION ...........................................................................................

EXHAUST SYSTEM COUNTERWEIGHT EXHAUST LWB .........................................................................................................

COUNTERWIGHT EXHAUST SWB ...........................................................................................................

EXHAUST WRAPS FOR PAPER INDUSTRY ............................................................................................

GM 4.3L, GASOLINE AND LPG .................................................................................................................

OVERHEAD EXHAUST LWB .....................................................................................................................

OVERHEAD EXHAUST SWB .....................................................................................................................

F FAN ASSEMBLY GM 4.3L GASOLINE AND LPG - PSI .........................................................................................................

FAN MOUNT ASSEMBLY GM 4.3L LPG AND GASOLINE - PSI .........................................................................................................

FAN PULLY KUBOTA DIESEL - (3.6L, 3.8L) ..................................................................................................................

FAN SHROUD WITH RADIATOR SCREEN DIESEL ........................................................................................................................................................

GASOLINE AND LPG .................................................................................................................................

FAN SHROUD WITHOUT RADIATOR SCREEN DIESEL ........................................................................................................................................................

GASOLINE AND LPG .................................................................................................................................

FENDER EXTENSIONS ..................................................................................................................................

iv

See Service Manual for service procedures.

2-64 3-22 3-20 5-4 10-34 5-38 5-40 5-10 5-6 5-8 5-98 3-2 2-24 2-66 2-67 3-27 2-4 2-8 2-12 3-12 2-6 2-10

3-16 3-14 2-27 2-20 3-10 2-18 3-8 1-8

©2015 HYSTER COMPANY

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UNIT CODE R005 NORTH AMERICA

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FIRE EXTINGUISHER ....................................................................................................................................

FLOOR PLATES AND COVERS SHEET 1 OF 2 ............................................................................................................................................

SHEET 2 OF 2 ............................................................................................................................................

FLYWHEEL AND HOUSING GM 4.3L GASOLINE AND LPG - PSI .........................................................................................................

KUBOTA DIESEL - (3.6L, 3.8L) ..................................................................................................................

FORKS OPTIONAL LATCH .....................................................................................................................................

POLISHED FORK WITH FULL BOTTOM TAPER - CLASS III AND CLASS IV .........................................

STANDARD TAPER CLASS III AND CLASS IV .........................................................................................

FORWARD CLUTCH SINGLE SPEED TRANSMISSION ..............................................................................................................

FORWARD CLUTCH, HIGH DUAL SPEED TRANSMISSION .................................................................................................................

FORWARD CLUTCH, LOW DUAL SPEED TRANSMISSION .................................................................................................................

FREE LIFT CYLINDER THREE STAGE FULL FREE LIFT ..............................................................................................................

FUEL CAP GASOLINE AND DIESEL ............................................................................................................................

FUEL FILTER KUBOTA DIESEL - (3.6L) ...........................................................................................................................

FUEL INJECTION PUMP KUBOTA DIESEL - (3.8L) ...........................................................................................................................

FUEL PUMP KUBOTA DIESEL - (3.6L) ...........................................................................................................................

FUEL RAIL KUBOTA DIESEL - (3.8L) ...........................................................................................................................

FUEL SENDER AND ATTACHING PARTS GM 4.3L GASOLINE - PSI OPTION ...........................................................................................................

FUEL SENDING UNIT KUBOTA 3.6L DIESEL ................................................................................................................................

FUEL SYSTEM GM 4.3L LPG - PSI OPTION .......................................................................................................................

GM 4.3L GASOLINE - PSI OPTION ...........................................................................................................

KUBOTA DIESEL - (3.8L) ...........................................................................................................................

FULL SUSPENSION SEAT MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON SWIVEL - SHEET 1 OF 3 ......................

MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON SWIVEL - SHEET 2 OF 3 ......................

FUSE BOX GM 4.3L LPG - PSI OPTION .......................................................................................................................

14-56 1-54 1-56 3-18 2-26 1-51 1-50 1-48 6-18 6-32 6-30 13-28 4-20 2-60 2-57 2-59 2-46 4-12 4-14 4-16 4-10 4-18 1-26 1-30 5-32

G GEAR CASE KUBOTA DIESEL - (3.6L, 3.8L) .................................................................................................................. 2-77 GEAR PUMP ................................................................................................................................................... 10-8 GOVERNOR KUBOTA DIESEL - (3.6L) ........................................................................................................................... 2-54

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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GOVERNOR ACTUATOR AND PLUG KUBOTA DIESEL - (3.6L) ........................................................................................................................... 2-56 H HAND LEVERS FOUR FUNCTION - WITH DETENTED LEVERS .......................................................................................

FOUR FUNCTION - WITHOUT DETENTED LEVERS ...............................................................................

THREE FUNCTION - WITH DETENTED LEVERS .....................................................................................

THREE FUNCTION - WITHOUT DETENTED LEVERS .............................................................................

HEADER HOSE AUXILIARY TUBE EXTENSIONS THREE STAGE FULL FREE- LIFT - INTEGRAL SIDE-SHIFT CARRIAGE ...............................................

THREE STAGE FULL FREE- LIFT - ATTACHMENT CARRIAGE .............................................................

TWO STAGE FULL FREE- LIFT - INTEGRAL SIDE-SHIFT CARRIAGE ...................................................

TWO STAGE FULL FREE- LIFT - ATTACHMENT CARRIAGE .................................................................

TWO STAGE LIMITED FREE-LIFT - INTEGRAL SIDE-SHIFT CARRIAGE ..............................................

TWO STAGE LIMITED FREE-LIFT - ATTACHMENT CARRIAGE .............................................................

HEADER HOSE AUXILIARY TUBE EXTENSIONS WITH QUICK DISCONNECTS THREE STAGE FULL FREE-LIFT - STANDARD CARRIAGE ...................................................................

THREE STAGE FULL FREE-LIFT - INTEGRAL SIDE-SHIFT CARRIAGE ................................................

THREE STAGE FULL FREE-LIFT - ATTACHMENT CARRIAGE ..............................................................

TWO STAGE FULL FREE- LIFT - STANDARD CARRIAGE ......................................................................

TWO STAGE FULL FREE-LIFT - INTEGRAL SIDE-SHIFT CARRIAGE ....................................................

TWO STAGE FULL FREE-LIFT - ATTACHMENT CARRIAGE ..................................................................

TWO STAGE LIMITED FREE-LIFT - STANDARD CARRIAGE ..................................................................

TWO STAGE LIMITED FREE-LIFT - INTEGRAL SIDE-SHIFT CARRIAGE ..............................................

TWO STAGE LIMITED FREE-LIFT - ATTACHMENT CARRIAGE .............................................................

HEATER HOSE DIESEL ........................................................................................................................................................

GAS .............................................................................................................................................................

LPG .............................................................................................................................................................

HOOD ASSEMBLY .........................................................................................................................................

HOSE GROUPS HYDRAULIC FILTER ......................................................................................................................................

HYDRAULIC SUPPLY AND RETURN ............................................................................................................

I IMPACT SENSOR ...........................................................................................................................................

INJECTION PIPE KUBOTA DIESEL - (3.8L) ...........................................................................................................................

INJECTION PUMP KUBOTA DIESEL - (3.6L) ...........................................................................................................................

INJECTION PUMP HOUSING KUBOTA DIESEL - (3.6L) ...........................................................................................................................

INJECTOR HARNESS KUBOTA DIESEL - (3.8L) ...........................................................................................................................

INLET AND EXHAUST VALVES KUBOTA DIESEL - (3.8L) ...........................................................................................................................

INLET MANIFOLD KUBOTA DIESEL - (3.6L) ...........................................................................................................................

vi

See Service Manual for service procedures.

10-14 10-16 10-10 10-12 14-4 14-10 14-3 14-8 14-2 14-6 14-20 14-28 14-34 14-16 14-26 14-32 14-12 14-24 14-30 1-19 1-17 1-18 1-4 10-6 10-2 5-52 2-47 2-52 2-51 2-50 2-40 2-61

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KUBOTA DIESEL - (3.8L) ...........................................................................................................................

INNER MAST THREE STAGE FULL FREE-LIFT ..............................................................................................................

INNER MAST AND FREE-LIFT THREE STAGE FULL FREE-LIFT (→ 4/2013) ..........................................................................................

THREE STAGE FULL FREE-LIFT (4/2013 →) ..........................................................................................

INSTRUMENT CLUSTER ...............................................................................................................................

INTAKE AIR FUEL MODULE GM 4.3L GASOLINE ...................................................................................................................................

INTEGRAL SIDE-SHIFT CARRIAGE ASSEMBLY CHAIN ANCHOR GROUPS ........................................................................................................................

THREE STAGE FULL FREE LIFT ..............................................................................................................

TWO STAGE FULL FREE LIFT ..................................................................................................................

TWO STAGE LIMITED FREE-LIFT ............................................................................................................

INTERMEDIATE MAST THREE STAGE FULL FREE LIFT ..............................................................................................................

L LABELS EXTERIOR ..................................................................................................................................................

HYDRAULIC CONTROL LABELS - MINI LEVER MODULES ....................................................................

HYDRAULIC CONTROL LABELS - CONTROL LEVER .............................................................................

INTERIOR ...................................................................................................................................................

LIFTING EYES GASOLINE AND DIESEL ............................................................................................................................

LIGHTS WORK, REAR DRIVE, AND BRAKE/TAIL - WITH OVERHEAD GUARD ..................................................

WORK, REAR DRIVE, AND BRAKE/TAIL - WITH CAB .............................................................................

LOAD BACK REST EXTENSION ....................................................................................................................

LOAD WEIGH ELECTRICAL ..........................................................................................................................

LPG CONVERTER GM 4.3L LPG - PSI OPTION .......................................................................................................................

LPG LOCK OFF GM 4.3L - PSI OPTION ...............................................................................................................................

LPG REGULATOR AND MIXER GM 4.3L - PSI OPTION ...............................................................................................................................

LPG TANK BRACKET GM 4.3L - SWING OUT, DROP DOWN (1/2013 →) ..................................................................................

GM 4.3L - SWING OUT (→ 1/2013) ...........................................................................................................

GM 4.3L - SWING OUT (1/2013 →) ...........................................................................................................

SWING OUT, DROP DOWN (→ 1/2013) ...................................................................................................

2-62 13-10 13-12 13-16 5-54 3-40 14-48 14-44 14-40 14-36 13-6

1-38 1-44 1-46 1-42 14-62 5-26 5-28 1-52 5-50 4-25 4-26 4-24 4-34 4-38 4-42 4-30

M MAIN LIFT THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-20 MAIN LIFT CYLINDER THREE STAGE FULL FREE LIFT .............................................................................................................. 13-24 MANUAL HYDRAULIC CONTROLS AND CONTROL VALVES ..................................................................... 15-7

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See Service Manual for service procedures.

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MAST THREE STAGE FULL FREE LIFT - HEADER HOSE .................................................................................

THREE STAGE FULL FREE LIFT - HEADER HOSE AUXILIARY TUBE EXTENSIONS (STANDARD CARRIAGE) ................................................................................................................................................

THREE STAGE FULL FREE LIFT - CARRIAGE ........................................................................................

TWO STAGE FULL FREE LIFT - OUTER MAST AND MAIN LIFT ............................................................

TWO STAGE FULL FREE LIFT - INNER MAST AND FREE LIFT (→ 4/2013) .........................................

TWO STAGE FULL FREE LIFT - INNER MAST AND FREE LIFT (4/2013 →) .........................................

TWO STAGE FULL FREE LIFT - FREE LIFT CYLINDER ..........................................................................

TWO STAGE FULL FREE LIFT - HEADER HOSE .....................................................................................

TWO STAGE FULL FREE LIFT - HEADER HOSE AUXILIARY TUBE EXTENSIONS (STANDARD CARRIAGE) ................................................................................................................................................

TWO STAGE FULL FREE LIFT - CARRIAGE ............................................................................................

TWO STAGE LIMITED FREE LIFT - OUTER MAST AND MAIN LIFT .......................................................

TWO STAGE LIMITED FREE LIFT - INNER MAST ...................................................................................

TWO STAGE LIMITED FREE LIFT - MAIN LIFT CYLINDER (H80-90FT) .................................................

TWO STAGE LIMITED FREE LIFT - MAIN LIFT CYLINDER (H100-120FT) .............................................

TWO STAGE LIMITED FREE LIFT - HEADER HOSE ...............................................................................

TWO STAGE LIMITED FREE LIFT - HEADER HOSE AUXILIARY TUBE EXTENSIONS (STANDARD CARRIAGE) ................................................................................................................................................

TWO STAGE LIMITED FREE LIFT - CARRIAGE .......................................................................................

MAST TILT SENSOR ......................................................................................................................................

MINI-LEVER CONTROLS WITH ARMREST - THREE FUNCTION ......................................................................................................

WITH ARMREST - FOUR FUNCTION ........................................................................................................

MINI-LEVER HYDRAULIC CONTROLS AND CONTROL VALVES ...............................................................

MIRROR ..........................................................................................................................................................

MONOTROL PEDAL ASSEMBLY → S/N R005V02608K ................................................................................................................................

MUD GUARDS ................................................................................................................................................

13-32 13-36 13-38 12-2 12-6 12-10 12-22 12-26 12-30 12-32 11-2 11-6 11-10 11-12 11-14 11-16 11-18 5-48 5-56 5-58 15-6 14-54 4-44 1-16

N NON SUSPENSION SEAT WITHOUT ELECTRONIC CONTROLS ...................................................................................................... 1-20 WITHOUT ELECTRONIC CONTROLS - OPTIONAL ................................................................................. 1-22 NOZZLE HOLDER AND GLOW PLUG KUBOTA DIESEL - (3.6L) ........................................................................................................................... 2-49 O OIL COOLER KUBOTA DIESEL - (3.6L, 3.8L) ..................................................................................................................

OIL PAN KUBOTA DIESEL - 3.6L, 3.8L .....................................................................................................................

OIL PUMP GM 4.3L GASOLINE AND LPG ..................................................................................................................

OIL SEPARATOR KUBOTA DIESEL - (3.8L) ...........................................................................................................................

OUTER MAST THREE STAGE FULL FREE-LIFT ..............................................................................................................

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2-31 2-76 3-44 2-30 13-2

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OUTLET SECTION ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 10-42 OVERHEAD GUARD ...................................................................................................................................... 1-10 P PARK BRAKE ASSEMBLY MANUAL WITH ONE CABLE - NMHG DRIVE AXLE .................................................................................

MANUAL WITH TWO CABLES - DANA .....................................................................................................

PISTON AND CRANKSHAFT KUBOTA DIESEL - (3.6L) ...........................................................................................................................

KUBOTA DIESEL - (3.8L) ...........................................................................................................................

POWER DISTRIBUTION MODULE ................................................................................................................

PRE-CLEANER AND MOUNT DIESEL ........................................................................................................................................................

DIESEL ENGINE - WITH AIR CONDITIONING ..........................................................................................

PULLEY AND TENSIONER GM 4.3L GASOLINE AND LPG - PSI .........................................................................................................

R REAR DRIVE HANDLE ...................................................................................................................................

RED SEAT BELT .............................................................................................................................................

RELAY KUBOTA DIESEL ........................................................................................................................................

REMOTE KEY SWITCH ..................................................................................................................................

REVERSE CLUTCH DUAL SPEED TRANSMISSION .................................................................................................................

SINGLE SPEED TRANSMISSION ..............................................................................................................

ROCKER ARM ASSEMBLY WITH INLET AND EXHAUST VALVES - KUBOTA DIESEL (3.6L) ............................................................

ROCKER ARM SHAFT KUBOTA DIESEL - (3.8L) ...........................................................................................................................

S SEAT ATTACHING PARTS NOT INCLUDED WITH SEAT - SHEET 3 OF 3 ..........................................................................................

SEATS SEMI SUSPENSION SEAT - MANUAL AND ELECTRO-HYDRAULIC ......................................................

SENSORS KUBOTA DIESEL - (3.8L) ...........................................................................................................................

SPARK PLUGS AND WIRES GM 4.3L GASOLINE AND LPG - PSI OPTION ...........................................................................................

START OPTIONS ............................................................................................................................................

STARTER GM 4.3L LPG AND GASOLINE - PSI .........................................................................................................

KUBOTA DIESEL - (3.6L, 3.8L) ..................................................................................................................

STEER AXLE ..................................................................................................................................................

STEER CONTROL UNIT .................................................................................................................................

STEER CYLINDER .........................................................................................................................................

STEER WHEELS AND TIRES ........................................................................................................................

STEERING COLUMN AND ATTACHING PARTS .......................................................................................... ©2015 HYSTER COMPANY

See Service Manual for service procedures.

9-30 9-28 2-42 2-44 5-34 4-8 4-9 3-24 14-50 15-6 5-31 5-55 6-34 6-20 2-38 2-41

1-32 1-24 2-86 5-42 15-2 5-46 2-91 8-12 8-10 8-16 8-18 8-4 ix

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STEERING COLUMN ASSEMBLY DIESEL ........................................................................................................................................................

8-8 GASOLINE AND LPG .................................................................................................................................

8-6 STEERING HOSES .........................................................................................................................................

8-2 STROBE LIGHT LED ............................................................................................................................................................. 14-52 SWIVEL SEATS .............................................................................................................................................. 15-2 T THERMOSTAT AND WATER OUTLET HOUSING GM 4.3L LPG - PSI OPTION .......................................................................................................................

GM 4.3L GASOLINE - PSI OPTION ...........................................................................................................

THROTTLE BODY GM 4.3L LPG - PSI OPTION .......................................................................................................................

GM 4.3L GASOLINE ...................................................................................................................................

THROTTLE CABLE ASSEMBLY KUBOTA 3.6L DIESEL ................................................................................................................................

THROTTLE PEDAL ASSEMBLY AND ATTACHING PARTS MONOTROL (S/N R005V02609K →) ........................................................................................................

STANDARD PEDAL ....................................................................................................................................

TILT HOSES ....................................................................................................................................................

TILT CYLINDER AND MAST INSTALLATION ................................................................................................

TILT CYLINDERS ............................................................................................................................................

TORQUE CONVERTER GM 4.3L LPG ..............................................................................................................................................

TRANSMISSION DUAL SPEED - TWO PIECE HOUSING ....................................................................................................

DUAL SPEED - SECTION 1 OF 2 ..............................................................................................................

DUAL SPEED - SECTION 2 OF 2 ..............................................................................................................

SINGLE SPEED - TWO PIECE HOUSING .................................................................................................

SINGLE SPEED - SECTION 1 OF 2 ...........................................................................................................

SINGLE SPEED - SECTION 2 OF 2 ...........................................................................................................

TRANSMISSION CONTROL VALVE ASSEMBLY ..........................................................................................

TRANSMISSION COOLING LINES DIESEL WITH STANDARD RADIATOR .....................................................................................................

GASOLINE AND LPG WITH STANDARD RADIATOR ...............................................................................

WITH EXTERNAL OIL COOLER - GASOLINE, LPG AND DIESEL ...........................................................

TRANSMISSION MOUNT ...............................................................................................................................

TURBO INLET PIPE KUBOTA DIESEL - (3.8L) ...........................................................................................................................

TURBOCHARGER KUBOTA DIESEL - (3.6L) ...........................................................................................................................

KUBOTA DIESEL - (3.8L) ...........................................................................................................................

TURBOCHARGER OIL PLUMBING KUBOTA DIESEL - (3.6L) ...........................................................................................................................

KUBOTA DIESEL - (3.8L) ...........................................................................................................................

TWO STAGE FULL FREE LIFT MAIN LIFT CYLINDER - H80-90FT ............................................................................................................

MAIN LIFT CYLINDER - H100-120FT ........................................................................................................

x

See Service Manual for service procedures.

3-28 3-29 4-23 4-22 4-28 4-48 4-46 10-44 10-46 10-50 6-8 6-22 6-24 6-26 6-10 6-11 6-14 6-29 6-2 6-4 6-6 6-9 2-73 2-69 2-70 2-74 2-75 12-14 12-18

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

V VALVE ASSEMBLY OUTLET SECTION - MANUAL CONTROL, THREE AND FOUR FUNCTION ...........................................

VALVE ASSEMBLY, AUXILIARY ONE AND TWO MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ...............................................................

VALVE ASSEMBLY, AUXILIARY ONE SECTION ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION .......................................................

VALVE ASSEMBLY, AUXILIARY TWO SECTION ELECTRONIC CONTROL VALVE - FOUR FUNCTION .............................................................................

VALVE ASSEMBLY, LIFT AND LOWER ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION .......................................................

VALVE ASSEMBLY, LIFT AND TILT MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ...............................................................

VALVE ASSEMBLY, TILT SECTION ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION .......................................................

VALVE COVER AND INLET MANIFOLD GM 4.3L GASOLINE AND LPG - PSI .........................................................................................................

VENT LINE GROUP ........................................................................................................................................

W WATER BYPASS GM 4.3L GASOLINE ...................................................................................................................................

WATER PUMP KUBOTA DIESEL - (3.6L, 3.8L) ..................................................................................................................

WATER PUMP FLANGE AND THERMOSTAT KUBOTA DIESEL - (3.6L) ...........................................................................................................................

KUBOTA DIESEL - (3.8L) ...........................................................................................................................

WET BRAKE ASSEMBLY ...............................................................................................................................

NMHG .........................................................................................................................................................

WIDE TREAD AND DUAL TREAD TIRES ......................................................................................................

WIRE HARNESS ADAPTER - LOW FUEL PRESSURE .........................................................................................................

AIR CONDITIONER ....................................................................................................................................

ALTERNATOR TO BATTERY DISCONNECT SWITCH - KUBOTA 3.8L DIESEL .....................................

ALTERNATOR TO STARTER - KUBOTA 3.8L DIESEL .............................................................................

ELECTRONIC CONTROL VALVE - THREE FUNCTION ...........................................................................

ELECTRONIC CONTROL VALVE - FOUR FUNCTION .............................................................................

ENGINE - KUBOTA 3.8L DIESEL ...............................................................................................................

ENGINE - KUBOTA DIESEL (3.6L) ............................................................................................................

LEFT HAND CHASSIS - GM 4.3L LPG (WITHOUT PREMIUM LOW FUEL SENSOR) .............................

LIGHTS - WITH OVERHEAD GUARD ........................................................................................................

RIGHT HAND CHASSIS - GM 3.4L GAS/LPG AND KUBOTA 3.8L DIESEL .............................................

RIGHT HAND CHASSIS - KUBOTA DIESEL (3.6L) ...................................................................................

SEALED ALTERNATOR - GM 4.3L GASOLINE AND LPG ........................................................................

TRANSMISSION - SINGLE SPEED ...........................................................................................................

TRANSMISSION - DUAL SPEED ...............................................................................................................

WIRE HARNESS (ALTERNATE) RIGHT HAND CHASSIS - KUBOTA DIESEL (3.6L) ...................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

10-26 10-24 10-38 10-40 10-32 10-22 10-36 3-38 10-48

3-46 2-90 2-88 2-89 7-20 7-30 15-2 5-60 5-62 5-66 5-68 5-86 5-88 5-94 5-100 5-102 5-122 5-104 5-110 5-124 5-126 5-128 5-116

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

WIRE HARNESS (ENGINE) GM 4.3L LPG - PSI OPTION .......................................................................................................................

WIRE HARNESS BRACKET KUBOTA DIESEL - (3.8L) ...........................................................................................................................

WIRE HARNESS-COWL ELECTRO-HYDRAULICS WITH FORWARD/REVERSE - WITH HYDRAULIC PUMP SOLENOID ..........

ELECTRO-HYDRAULICS WITH MONOTROL PEDAL - WITH HYDRAULIC PUMP SOLENOID .............

MANUAL HYDRAULICS WITH FORWARD/REVERSE - WITH HYDRAULIC PUMP SOLENOID ............

MANUAL HYDRAULICS WITH MONOTROL PEDAL - WITH HYDRAULIC PUMP SOLENOID ...............

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See Service Manual for service procedures.

5-90 2-87 5-74 5-70 5-82 5-78

©2015 HYSTER COMPANY

UNIT CODE R005 NORTH AMERICA

10/2015

ABBREVIATIONS QUICK REFERENCE SHEET 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 Stacking

S/N

Serial Number

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 Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

ECH-6

Empty Container Handler - 6 High Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High Stacking

UL Type G

Gasoline-Powered Safety Rating

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 Read Only Memory

U/S

Undersize

EPA

US Environmental Protection Agency

UL

Underwriters Laboratory

EPROM

Electrically Programmable Read Only Memory

V

Volts

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

xiv

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

See Service Manual for service procedures.

©2015 HYSTER COMPANY

10/2015

UNIT CODE R005 NORTH AMERICA

HOW TO FIND THE DESIRED PART NUMBER

1.

2.

3.

4.

5.

WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: 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.

Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).

Locate the assembly the required part is used on and turn to the page indicated for that assembly.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN: Use the Numerical Index (Page 16-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL:

6.

The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

Parts Supersession 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 (FFigure 10)

7.

8.

Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc.

Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

Indented descriptions under the DESCRIPTION column are used to indicate assemblies and

©2015 HYSTER COMPANY

subparts of assemblies. In the example on the previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE. 9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

10. Serial number breaks identify the most current parts information and are shown as follows: → S/N D001H2628 Indicates last serial number affected.

S/N D001H2629 → Indicates the first serial number affected.

S/N D001H1553 ↔ S/N D001H3291 Indicates a range of serial numbers affected.

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows: → S/N Pending Per ECN 63243 Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 → Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows: → D/B 3/00 Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 → Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ↔ D/B 4/00 Indicates a range of production dates of the item affected.

Contact your local dealer for Hyster lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS: When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Hyster lift trucks.

See Service Manual for service procedures.

xv