Hyster A099 (E80XN, E100XN, E100XNS, E120XN) Forklift Parts Manual

E80XN, E100XN, E100XNS, E120XN (A099)

4051566 07/2015

©2015 HYSTER COMPANY

UNIT CODE A099 NORTH AMERICA

07/2015

SECTIONS 1

FRAME

2

ELECTRICAL SYSTEM

3

DRIVE UNIT

4

STEERING SYSTEM

5

BRAKE/ACCELERATOR SYSTEM

6

HYDRAULIC SYSTEM

7

MAST-TWO STAGE LIMITED FREE-LIFT

8

MAST-THREE STAGE FULL FREE-LIFT

9

MAST-TWO STAGE FULL FREE-LIFT

10

OPTIONS

11

FIELD CONVERSION KITS

12

NUMERICAL INDEX

This Parts Manual is divided into 12 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

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07/2015

UNIT CODE A099 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

A ACCELERATOR PEDAL ASSEMBLY (MONOTROL) ....................................................................................

ACCELERATOR PEDAL ASSEMBLY (STANDARD) .....................................................................................

ACCUMULATOR .............................................................................................................................................

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

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

ARMREST SLIDER ASSEMBLY .....................................................................................................................

AUXILIARY KEYSWITCH ...............................................................................................................................

AUXILIARY TUBE EXTENSIONS THREE STAGE FULL FREE-LIFT - WITHOUT QUICK DISCONNECT FITTINGS ...................................

THREE STAGE FULL FREE-LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ....................................................................................................................................................................

THREE STAGE FULL FREE-LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ...............

TWO STAGE FULL FREE- LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ......

TWO STAGE FULL FREE-LIFT - WITHOUT QUICK DISCONNECT FITTINGS .......................................

TWO STAGE FULL FREE-LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ...................

TWO STAGE LIMITED FREE LIFT - WITHOUT QUICK DISCONNECT FITTINGS ..................................

TWO STAGE LIMITED FREE LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ....................................................................................................................................................................

TWO STAGE LIMITED FREE LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ..............

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

BATTERY COMPARTMENT AND COVERS HORIZONTAL BATTERY REMOVAL (→ 4/2013) .....................................................................................

HORIZONTAL BATTERY REMOVAL (4/2013 →) .....................................................................................

VERTICAL BATTERY REMOVAL - E80-120XN (→ 4/2013) .....................................................................

VERTICAL BATTERY REMOVAL - E100-120XN (4/2013 →) ...................................................................

VERTICAL BATTERY REMOVAL - E80-E100XNS WITH STANDARD OVERHEAD GUARD ..................

VERTICAL BATTERY REMOVAL - E80-E100XNS WITH FLAT OVERHEAD GUARD (→ 4/2013) .........

VERTICAL BATTERY REMOVAL - E80-E100XNS WITH FLAT OVERHEAD GUARD (4/2013 →) .........

BATTERY CONNECTOR RAPID CHARGE OPTION ..........................................................................................................................

WITH FLAT OVERHEAD GUARD - LWB (E100-120XN) (→ 11/2014) .....................................................

WITH FLAT OVERHEAD GUARD - LWB (E100-120XN) (11/2014 →) .....................................................

WITH FLAT OVERHEAD GUARD - SWB (E80-100XNS) (→ 11/2014) ....................................................

WITH FLAT OVERHEAD GUARD - SWB (E80-100XNS) (11/2014 →) ....................................................

WITH STANDARD OVERHEAD GUARD - LWB (E100-120XN) (→ 11/2014) ..........................................

WITH STANDARD OVERHEAD GUARD - LWB (E100-120XN) (11/2014 →) ..........................................

WITH STANDARD OVERHEAD GUARD - SWB (E80-100XNS) ...............................................................

BRAKE ASSEMBLY ........................................................................................................................................

BRAKE SYSTEM .............................................................................................................................................

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

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

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

CONTACTOR AND FUSE ASSEMBLY ..........................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

5-9 5-8 10-4 11-2 11-3 1-34 10-2 10-52 10-54 10-56 10-62 10-59 10-64 10-44 10-46 10-48 10-6 1-36 1-40 1-44 1-46 1-48 1-50 1-52 2-20 2-11 2-14 2-16 2-18 2-6 2-8 2-10 5-4 5-2

8-38 9-28 7-18 2-22

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

CONTACTOR ASSEMBLY UL-E ............................................................................................................................................................

UL-EE ..........................................................................................................................................................

CONTROL PANELS AND CONTACTORS .....................................................................................................

CONTROLLER ASSEMBLY PUMP AND TRACTION (11/2014 →) ........................................................................................................

PUMP MOTOR (→ 11/2014) ......................................................................................................................

TRACTION MOTOR (→ 11/2014) ..............................................................................................................

CONVERSION KIT COUNTERWEIGHT ........................................................................................................................................

COUNTERWEIGHT COVER WITH RAPID CHARGE OPTION ................................................................................................................

D DASH AND STEERING COLUMN COVERS FIXED COLUMN .........................................................................................................................................

TELESCOPIC COLUMN .............................................................................................................................

DC CONVERTER AND ATTACHING PARTS ................................................................................................

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

DISPLAY LOW MOUNT ..............................................................................................................................................

DISPLAY GROUP AND HARNESS HIGH MOUNT .............................................................................................................................................

DRIP SHIELD AND STATIC STRAP ...............................................................................................................

DRIVE AXLE AND ATTACHING PARTS ........................................................................................................

DRIVE AXLE ASSEMBLY WET BRAKE - RIGHT AND LEFT HAND HUBS ........................................................................................

WET BRAKE - BRAKES AND DIFFERENTIAL ..........................................................................................

WET BRAKE - INPUT PINION CARRIER ...................................................................................................

DRIVE TIRE AND WHEEL E100-120XN ................................................................................................................................................

E80XN-100XNS ..........................................................................................................................................

E ELECTRICAL ARRANGEMENT .....................................................................................................................

F FENDERS .......................................................................................................................................................

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

FLOORPLATES AND STEPS .........................................................................................................................

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

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

POLISHED FULL BOTTOM TAPER OPTIONAL - CLASS III AND CLASS IV ...........................................

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

FORKS WITH LEVER STANDARD TAPER OPTIONAL - CLASS III AND CLASS IV ....................................................................

FREE-LIFT THREE STAGE FULL FREE-LIFT (→ 10/2013) ........................................................................................ ii

See Service Manual for service procedures.

2-23 2-24 2-21 2-30 2-26 2-28 1-4 1-5

1-54 1-56 10-14 3-13 2-42 2-40 1-13 3-2 3-4 3-8 3-11 3-16 3-15 2-4 1-12 10-10 1-10 1-61 1-60 1-64 1-58 1-62 8-26

©2015 HYSTER COMPANY

07/2015

UNIT CODE A099 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

THREE STAGE FULL FREE-LIFT (10/2013 →) ........................................................................................

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

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

FULL SUSPENSION SEAT MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON SWIVEL - SHEET 1 OF 4 ......................

RECLINER AND DAMPER KITS - SHEET 2 OF 4 .....................................................................................

SERVICE KITS FOR NON SWIVEL AND SWIVEL - SHEET 3 OF 4 .........................................................

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

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

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

HOOD WITH FLAT OVERHEAD GUARD - AND SHORT WHEEL BASE (E80-100XNS) .....................................

WITH FLAT OVERHEAD GUARD - AND LONG WHEEL BASE (E100-120XN) ........................................

WITH STANDARD OVERHEAD GUARD - AND SHORT WHEEL BASE (E80-100XNS) ..........................

WITH STANDARD OVERHEAD GUARD - AND LONG WHEEL BASE (E100-120XN) .............................

HYDRAULIC MOTOR ASSEMBLY WITH 29 CC PUMP (11/2014 →) ...............................................................................................................

HYDRAULIC CONTROL VALVE INLET SECTION - MANUAL HYDRAULIC .................................................................................................

INLET SECTION - ELECTRO-HYDRAULIC ...............................................................................................

LIFT, TILT, AND AUXILIARY - MANUAL HYDRAULIC ..............................................................................

LIFT, TILT, AND AUXILIARY - ELECTRO-HYDRAULIC ............................................................................

HYDRAULIC CONTROL VALVE AND FITTINGS ELECTRO-HYDRAULIC - THREE AND FOUR FUNCTION .......................................................................

MANUAL HYDRAULIC - THREE AND FOUR FUNCTION .........................................................................

HYDRAULIC CONTROL VALVE ASSEMBLY ELECTRO-HYDRAULIC - THREE AND FOUR FUNCTION .......................................................................

MANUAL HYDRAULIC - THREE AND FOUR FUNCTION .........................................................................

HYDRAULIC HOSES STEERING ..................................................................................................................................................

HYDRAULIC MOTOR ASSEMBLY → 11/2014 ..................................................................................................................................................

WITH 33 CC PUMP (11/2014 →) ...............................................................................................................

HYDRAULIC PUMP 29 CC (11/2014 →) ....................................................................................................................................

33 CC ..........................................................................................................................................................

HYDRAULIC PUMP AND MOTOR MOUNTING WET SPLINE DRIVE 29 CC (11/2014 →) .................................................................................................

WET SPLINE DRIVE 33 CC .......................................................................................................................

HYDRAULIC SUPPLY AND RETURN PAGE 1 OF 2 ..............................................................................................................................................

PAGE 2 OF 2 ..............................................................................................................................................

HYDRAULIC TANK AND ATTACHING PARTS ..............................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

8-30 8-34 9-18 1-26 1-28 1-30

8-40 9-22 7-20 1-18 1-20 1-14 1-16 6-18 6-32 6-40 6-30 6-38 6-34 6-25 6-36 6-27 6-8 6-16 6-20 6-12 6-14 6-10 6-11 6-2 6-4 6-6

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

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

INNER MAST AND FREE-LIFT TWO STAGE FULL FREE-LIFT (→ 10/2013) ............................................................................................

TWO STAGE FULL FREE-LIFT (10/2013 →) ............................................................................................

INTEGRAL SIDE-SHIFT ASSEMBLY THREE STAGE FULL FREE-LIFT - E80XN ...............................................................................................

TWO AND THREE STAGE FULL FREE-LIFT - E100-120XN/E100XNS ...................................................

TWO STAGE FULL FREE-LIFT - E80XN ...................................................................................................

TWO STAGE LIMITED FREE LIFT CLASS III - ORFS FITTINGS .............................................................

TWO STAGE LIMITED FREE LIFT CLASS IV - ORFS FITTINGS .............................................................

INTEGRAL SIDE-SHIFT CARRIAGE 1067 MM (42 IN.) CLASS III - THREE STAGE FULL FREE-LIFT ..............................................................

THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III ..............................................................

THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV ..............................................................

TWO STAGE FULL FREE-LIFT - 1067 MM (42 IN.) CLASS III ..................................................................

TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III ..................................................................

TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV .................................................................

TWO STAGE LIMITED FREE-LIFT - 1067 MM (42 IN.) CLASS III ............................................................

TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS III ............................................................

TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS IV ............................................................

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

10-12 8-14 7-4 9-6 9-10 10-32 10-36 10-26 10-16 10-18 10-40 10-34 10-42 10-28 10-30 10-38 10-20 10-22 10-24 8-10

L LIGHTS ............................................................................................................................................................ 2-44 LOAD BACKREST EXTENSION ..................................................................................................................... 1-66 M MAIN LIFT THREE STAGE FULL FREE-LIFT ..............................................................................................................

TWO STAGE LIMITED FREE-LIFT (→ 10/2013) ......................................................................................

TWO STAGE LIMITED FREE-LIFT (10/2013 →) ......................................................................................

MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT ..............................................................................................................

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

TWO STAGE LIMITED FREE-LIFT - E80XN ..............................................................................................

TWO STAGE LIMITED FREE-LIFT - E100-120XN/E100XNS ....................................................................

MAIN WIRE HARNESS ELECTRIC HYDRAULIC - SHEET 1 OF 3 (11/2014 →) ............................................................................

ELECTRIC HYDRAULIC - SHEET 2 OF 3 (11/2014 →) ............................................................................

ELECTRIC HYDRAULIC - SHEET 3 OF 3 (11/2014 →) ............................................................................

MANUAL HYDRAULIC - SHEET 1 OF 3 (11/2014 →) ..............................................................................

MANUAL HYDRAULIC - SHEET 2 OF 3 (11/2014 →) ..............................................................................

MANUAL HYDRAULIC - SHEET 3 OF 3 (11/2014 →) ..............................................................................

MANUAL CONTROL LEVERS ........................................................................................................................

iv

See Service Manual for service procedures.

8-18 7-6 7-10 8-22 9-14 7-14 7-16 2-110 2-114 2-118 2-86 2-90 2-94 6-22

©2015 HYSTER COMPANY

07/2015

UNIT CODE A099 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

MASTER CYLINDER ......................................................................................................................................

MINI-LEVER CONTROLS 3 FUNCTION ...............................................................................................................................................

4 FUNCTION ...............................................................................................................................................

MIRROR PANORAMIC ...............................................................................................................................................

MIRRORS ........................................................................................................................................................

5-7 2-48 2-52 10-9 10-8

N NAMEPLATES AND LABELS HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-72 SHEET 1 OF 2 ............................................................................................................................................ 1-68 SHEET 2 OF 2 ............................................................................................................................................ 1-70 O OPERATOR MODULE ....................................................................................................................................

OUTER MAST THREE STAGE FULL FREE-LIFT (→ 10/2013) ........................................................................................

THREE STAGE FULL FREE-LIFT (10/2013 →) ........................................................................................

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

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

OVERHEAD GUARD FLAT ............................................................................................................................................................

STANDARD .................................................................................................................................................

P PARKING BRAKE VALVE ...............................................................................................................................

POWER CABLES E100-120XN (→ 11/2014) ..........................................................................................................................

E100-120XN (11/2014 →) ..........................................................................................................................

E80-100XNS (→ 11/2014) .........................................................................................................................

E80-100XNS (11/2014 →) .........................................................................................................................

1-2 8-2 8-6 7-2 9-2 1-8 1-6 5-6 2-36 2-38 2-32 2-34

R REAR DRIVE HANDLE ................................................................................................................................... 10-11 S SEAT ATTACHING PARTS NOT INCLUDED WITH SEAT - SHEET 4 OF 4 ..........................................................................................

SEATS NON SUSPENSION - WITH HIP RESTRAINTS .........................................................................................

NON SUSPENSION - LOW PROFILE WITH HIP RESTRAINTS ...............................................................

STEER AXLE WITHOUT SENSOR ...................................................................................................................................

STEER AXLE CYLINDER ...............................................................................................................................

STEER PUMP ASSEMBLY → 11/2014 ..................................................................................................................................................

11/2014 → ..................................................................................................................................................

STEER TIRE AND WHEEL ............................................................................................................................. ©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-32 1-22 1-24 4-2 4-6 4-16 4-18 4-8 v

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

STEERING ACCUMULATOR → 11/2014 ..................................................................................................................................................

STEERING COLUMN ASSEMBLY FIXED (→ 10/2013) ....................................................................................................................................

FIXED (10/2013 →) ....................................................................................................................................

TELESCOPIC (→ 10/2013) ........................................................................................................................

TELESCOPIC (10/2013 →) ........................................................................................................................

STEERING WHEEL AND COLUMN FIXED ..........................................................................................................................................................

TELESCOPIC ..............................................................................................................................................

T TAIL LIGHT MOUNTING .................................................................................................................................

TILT CYLINDER ..............................................................................................................................................

TILT CYLINDER AND ATTACHING PARTS ...................................................................................................

TILT SENSOR GROUP ...................................................................................................................................

TRACTION MOTOR ........................................................................................................................................

TRACTION SPEED LIMITER STANDARD AND INTEGRAL SIDE-SHIFT CARRIAGES ..........................................................................

4-20 4-11 4-12 4-14 4-15 4-9 4-10 10-7 6-44 6-42 2-58 3-14 2-56

V VEHICLE SYSTEM MANAGER ...................................................................................................................... 2-59 W WIRE HARNESS EMERGENCY DISCONNECT ....................................................................................................................

FRONT SWITCH .........................................................................................................................................

FRONT SWITCH .........................................................................................................................................

INTERFACE FRONT/REAR LIGHTS ..........................................................................................................

JUMPER ......................................................................................................................................................

LEFT HAND - WITHOUT TURN SIGNALS (10/2013 →) ...........................................................................

LIGHTS - LEFT HAND (→ 10/2013) ..........................................................................................................

MAIN - MANUAL HYDRAULIC SHEET 1 OF 3 (→ 11/2014) ....................................................................

MAIN - MANUAL HYDRAULIC SHEET 2 OF 3 (→ 11/2014) ....................................................................

MAIN - MANUAL HYDRAULIC SHEET 3 OF 3 (→ 11/2014) ....................................................................

MAIN - ELECTRO-HYDRAULIC SHEET 1 OF 3 (→ 11/2014) ..................................................................

MAIN - ELECTRO-HYDRAULIC SHEET 2 OF 3 (→ 11/2014) ..................................................................

MAIN - ELECTRO-HYDRAULIC SHEET 3 OF 3 (→ 11/2014) ..................................................................

MAIN CHASSIS - W/O LIGHTS ..................................................................................................................

MAIN LIGHTS CHASSIS - 48V ...................................................................................................................

MAIN LIGHTS CHASSIS - 80V ...................................................................................................................

MANUAL INTERLOCK ................................................................................................................................

RH LIGHT WITH FREEZER DISPLAY - WITH TURN SIGNALS-HIGH MOUNT (10/2013 →) .................

RH LIGHT WITH FREEZER DISPLAY - WITH TURN SIGNALS-LOW MOUNT (10/2013 →) ..................

RH LIGHT WITH STANDARD DISPLAY - WITHOUT TURN SIGNALS-HIGH MOUNT (10/2013 →) ......

RH LIGHT WITH STANDARD DISPLAY - WITHOUT TURN SIGNALS-LOW MOUNT (10/2013 →) .......

RH LIGHTS - STANDARD OPTION (→ 10/2013) .....................................................................................

RH LIGHTS - FREEZER OPTION (→ 10/2013) ........................................................................................

SEAT - MANUAL HYDRAULIC ...................................................................................................................

SEAT - MANUAL HYDRAULIC WITH SEAT BELT SEQUENCE MODULE ............................................... vi

See Service Manual for service procedures.

2-68 2-69 10-68 10-66 2-143 2-72 2-70 2-74 2-78 2-82 2-98 2-102 2-106 2-130 2-122 2-126 2-132 2-66 2-67 2-61 2-62 2-60 2-64 2-133 2-134

©2015 HYSTER COMPANY

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UNIT CODE A099 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

SEAT - E-HYDRAULIC ...............................................................................................................................

SEAT - E-HYDRAULIC WITH SEAT BELT SEQUENCE MODULE ...........................................................

STEERING COLUMN .................................................................................................................................

SYNCHRONOUS STEERING .....................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-136 2-138 2-140 2-142

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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

viii

See Service Manual for service procedures.

©2015 HYSTER COMPANY

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UNIT CODE A099 NORTH AMERICA

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

©2015 HYSTER COMPANY

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.

ix

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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 12-1) 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.

x

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

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.

©2015 HYSTER COMPANY

UNIT CODE A099 NORTH AMERICA

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IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2)

The first letter and three numbers indicate the truck unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number of the truck.

(5)

The final letter indicates the year of manufacture starting with "A" in 1957, 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.

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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IDENTIFICATION OF MAST SERIAL NUMBERS

(1) and (2)

The first letter and number indicates the mast 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 mast.

(5)

Carriage travel in millimeters stamped just below the serial number.

Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).

For pending production sequence numbers contact your local dealer for Hyster lift trucks.

LIFT EQUIPMENT IDENTIFICATION 1. Fork part number, capacity rating, plant code letter, and date of manufacture are stamped approximately six inches below the top of most forks.

2.

3.

4.

The carriage group number is stamped on the right hand side of the top crossmember (pin type) or on the back of the right hand end of the bottom crossmember (hook type). A date code has two letters in line with or below the carriage group number.

The mast identification number has a unit code, a letter indicating the plant of manufacture, and a serial number. Underneath the production sequence number is a four digit number that indicates the carriage travel in millimeters.

Tilt and lift cylinder group numbers are stamped on the cylinder shell.

Always refer to the group, serial, or part number when ordering service parts.

Modification of masts and carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". contact your dealer for Hyster lift trucks for information on these assemblies.

xii

See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE A099 NORTH AMERICA

07/2015

IDENTIFICATION OF ATTACHMENT AND SIDESHIFT CARRIAGE SERIAL NUMBERS

(1) and (2)

The first letter and three numbers indicate the attachment unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number.

For pending production sequence numbers contact your local dealer for Hyster lift trucks.

Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify the attachment.

Always refer to the group, serial, or part number when ordering service parts.

Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". Contact your dealer for Hyster lift trucks for information on these assemblies.

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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UNIT CODE A099 NORTH AMERICA

07/2015

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

SERVICE MAINTENANCE MANUALS, which provide service and overhaul procedures, and PARTS

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

PUBLICATION

HYSTER PART NUMBER

Operating Manual........................................................................................................................ 4051537 Service Manual (Complete)......................................................................................................... 4051578 Parts Manual............................................................................................................................... 4051566

xiv

See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE A099 NORTH AMERICA

07/2015

1

FRAME

07/2015

UNIT CODE A099 NORTH AMERICA

SECTION 1 FRAME DESCRIPTION

PAGE

ARMREST SLIDER ASSEMBLY .....................................................................................................................

BATTERY COMPARTMENT AND COVERS HORIZONTAL BATTERY REMOVAL (→ 4/2013) .....................................................................................

HORIZONTAL BATTERY REMOVAL (4/2013 →) .....................................................................................

VERTICAL BATTERY REMOVAL - E80-120XN (→ 4/2013) .....................................................................

VERTICAL BATTERY REMOVAL - E100-120XN (4/2013 →) ...................................................................

VERTICAL BATTERY REMOVAL - E80-E100XNS WITH STANDARD OVERHEAD GUARD ..................

VERTICAL BATTERY REMOVAL - E80-E100XNS WITH FLAT OVERHEAD GUARD (→ 4/2013) .........

VERTICAL BATTERY REMOVAL - E80-E100XNS WITH FLAT OVERHEAD GUARD (4/2013 →) .........

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

COUNTERWEIGHT COVER WITH RAPID CHARGE OPTION ................................................................................................................

DASH AND STEERING COLUMN COVERS FIXED COLUMN .........................................................................................................................................

TELESCOPIC COLUMN .............................................................................................................................

DRIP SHIELD AND STATIC STRAP ...............................................................................................................

FENDERS .......................................................................................................................................................

FLOORPLATES AND STEPS .........................................................................................................................

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

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

POLISHED FULL BOTTOM TAPER OPTIONAL - CLASS III AND CLASS IV ...........................................

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

FORKS WITH LEVER STANDARD TAPER OPTIONAL - CLASS III AND CLASS IV ....................................................................

FULL SUSPENSION SEAT MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON SWIVEL - SHEET 1 OF 4 ......................

RECLINER AND DAMPER KITS - SHEET 2 OF 4 .....................................................................................

SERVICE KITS FOR NON SWIVEL AND SWIVEL - SHEET 3 OF 4 .........................................................

HOOD WITH FLAT OVERHEAD GUARD - AND SHORT WHEEL BASE (E80-100XNS) .....................................

WITH FLAT OVERHEAD GUARD - AND LONG WHEEL BASE (E100-120XN) ........................................

WITH STANDARD OVERHEAD GUARD - AND SHORT WHEEL BASE (E80-100XNS) ..........................

WITH STANDARD OVERHEAD GUARD - AND LONG WHEEL BASE (E100-120XN) .............................

LOAD BACKREST EXTENSION .....................................................................................................................

NAMEPLATES AND LABELS HYDRAULIC CONTROL FUNCTIONS .......................................................................................................

SHEET 1 OF 2 ............................................................................................................................................

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

OPERATOR MODULE ....................................................................................................................................

OVERHEAD GUARD FLAT ............................................................................................................................................................

STANDARD .................................................................................................................................................

SEAT ATTACHING PARTS NOT INCLUDED WITH SEAT - SHEET 4 OF 4 ..........................................................................................

SEATS NON SUSPENSION - WITH HIP RESTRAINTS .........................................................................................

NON SUSPENSION - LOW PROFILE WITH HIP RESTRAINTS ............................................................... ©2015 HYSTER COMPANY

See Service Manual for service procedures.

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UNIT CODE A099 NORTH AMERICA

07/2015

OPERATOR MODULE (FIGURE 1-1)

1-2

See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE A099 NORTH AMERICA

07/2015

OPERATOR MODULE ITEM 1 2 3 4 5 6 7 8 9 10 11

PART NO.

DESCRIPTION

4040909 1528889 4040030 1530243 1698633 4040388 1690977 1528888 4040021 1527888 1698799

Cowl ....................................................................................................................

Capscrew ............................................................................................................

Side Plate Wldmt (RH) ........................................................................................

Insert ...................................................................................................................

Capscrew ............................................................................................................

Bulkhead Weldment ............................................................................................

Bolt ......................................................................................................................

Nut (Shoulder) ....................................................................................................

Side Plate Wldmt (LH) ........................................................................................

Capscrew ............................................................................................................

Plug (Yellow) (0.26 in) ........................................................................................

©2015 HYSTER COMPANY

QTY

See Service Manual for service procedures.

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