Hyster U005 (H80FT, H90FT, H100FT, H110FT, H120FT) Forklift Parts Manual

H80-H90-H100-H110-H120FT (U005)

4128542 01/2016

©2015 HYSTER COMPANY

UNIT CODE U005 NORTH AMERICA

01/2016

SECTIONS 1

FRAME

2

ENGINE ASSEMBLY - DIESEL

3

ENGINE ASSEMBLY - GM

4

ENGINE ASSEMBLY-KUBOTA LPG

5

FUEL SYSTEM

6

ELECTRICAL SYSTEM

7

TRANSMISSION

8

DRIVE AXLE

9

STEERING SYSTEM

10

BRAKE SYSTEM

11

HYDRAULIC SYSTEM

12

MAST-TWO STAGE LIMITED FREE-LIFT

13

MAST-TWO STAGE FULL FREE-LIFT

14

MAST-THREE STAGE FULL FREE-LIFT

15

OPTIONS

16

FIELD CONVERSION KITS

17

NUMERICAL INDEX

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01/2016

UNIT CODE U005 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

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

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

AIR FILTER 4.3L LPG .....................................................................................................................................................

AIR FILTER ASSEMBLY KUBOTA DIESEL - 3.6L, 3.8L .....................................................................................................................

KUBOTA LPG - 3.8L ...................................................................................................................................

AIR INTAKE KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

AIR INTAKE AND FILTER KUBOTA 3.8L LPG .....................................................................................................................................

PSI 4.3L LPG ..............................................................................................................................................

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

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

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

ALTERNATOR AND MOUNTING GM 4.3L GASOLINE AND LPG ..................................................................................................................

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

ANTI-STALL WITH MANUAL HYDRAULIC VALVE - GAS, LPG AND 3.6L DIESEL ......................................................

ARMREST ASSEMBLY MINI-LEVER MODULES - SEMI-SUSPENSION SEAT WITH HIP RESTRAINTS .....................................

MINI-LEVER MODULES - FULL SUSPENSION SEAT ..............................................................................

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

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

BATTERY CABLE FUSED-STANDARD ALTERNATOR - KUBOTA 3.6L DIESEL, 3.8L DIESEL/LPG ...................................

BATTERY CABLES GM 4.3L GASOLINE AND LPG ..................................................................................................................

KUBOTA 3.8L DIESEL/LPG ........................................................................................................................

BATTERY DISCONNECT GM 4.3L GS AND LPS ................................................................................................................................

KUBOTA 3.8L DIESEL/LPG - SAFETY OPTION ........................................................................................

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

BRAKE LINKAGE DUAL PEDAL - WET BRAKE ......................................................................................................................

SINGLE PEDAL - WET BRAKE ..................................................................................................................

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

15-53 16-7 5-14 5-13 5-12 5-2 5-4 5-10 5-8 5-6 6-40 6-41 6-42 2-107 11-28 1-66 1-68 11-64 15-48 6-34 6-36 6-30 6-38 6-32 10-10 10-6 10-2 10-14 2-86

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

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 - CONDENSER ASSEMBLY ..........................................................................

WITH AIR CONDITIONING - AIR CONDITIONER HEATER ......................................................................

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

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

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

WITHOUT AIR CONDITIONING - WINDOWS AND WIPERS-MECHANICALLY SEALED FRONT WINDOW .....................................................................................................................................................

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 ..............................................................................................................................

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

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

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

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

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

CARRIAGE LOCKOUT ROD CHARGE PUMP ASSEMBLY .........................................................................................................................

COMPRESSOR ASSEMBLY AND ATTACHING PARTS WITH CAB AND AIR CONDITIONING ........................................................................................................

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

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

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

ELECTRONIC CONTROL - THREE AND FOUR FUNCTION-WITH VARIABLE DISPLACEMENT PUMP ....................................................................................................................................................................

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

COOLING GASOLINE AND LPG - SHORT WHEEL BASE WITH EXTERNAL OIL COOLER ....................................

GASOLINE AND LPG - SHORT WHEEL BASE WITHOUT EXTERNAL OIL COOLER ............................

GASOLINE AND LPG - LONG WHEEL BASE WITH EXTERNAL COOLER .............................................

ii

See Service Manual for service procedures.

1-46 1-44 1-22 1-24 1-26 1-28 1-30 1-32 1-34 1-36 1-38 1-40 1-42 1-8 1-10 1-12 1-14 1-16 1-18 1-20 2-74 2-75 3-44 12-18 14-34 13-28 7-36 2-42 6-43 11-38 11-40 11-42 11-26 3-8 3-10 3-12

©2015 HYSTER COMPANY

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PAGE

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

KUBOTA DIESEL - WITHOUT EXTERNAL OIL COOLER WITH SHORT WHEELBASE ..........................

KUBOTA LPG - WITH EXTERNAL OIL COOLER ......................................................................................

KUBOTA LPG - WITHOUT EXTERNAL OIL COOLER WITH SHORT WHEELBASE ...............................

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

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

COWL ELECTRICAL ELECTRO-HYDRAULIC .............................................................................................................................

MANUAL HYDRAULIC ................................................................................................................................

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

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

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

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

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

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

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

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

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

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

D DIESEL PARTICULATE FILTER ATTACHING PARTS - KUBOTA 3.8L DIESEL ...........................................................................................

MUFFLER ASSEMBLY - KUBOTA 3.8L DIESEL .......................................................................................

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

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

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

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

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

DPF DISPLAY 3.8L KUBOTA DIESEL ................................................................................................................................

DRIVE AXLE AND ATTACHING PARTS WET BRAKE - DANA ..................................................................................................................................

WET BRAKE (NMHG) .................................................................................................................................

DRIVE AXLE ASSEMBLY WET BRAKE (DANA) - HOUSING AND HUB .............................................................................................

WET BRAKE (DANA) - DIFFERENTIAL .....................................................................................................

WET BRAKE (DANA) - BRAKE ASSEMBLY ..............................................................................................

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-12 2-16 4-2 4-4 1-4 2-65 6-8 6-6 1-70 3-36 3-42 2-66 2-68 3-40 2-50 2-51 2-46 2-48

2-38 2-40 8-24 2-76 16-6 3-52 6-46 6-44 8-2 8-12 8-4 8-6 8-10 8-14 8-18

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

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

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

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

E EGR COOLER KUBOTA DIESEL - 3.8L ..............................................................................................................................

EGR VALVE KUBOTA DIESEL - 3.8L ..............................................................................................................................

ELECTRICAL MOUNTING PLATE AND LIFTING EYE GM 4.3L GASOLINE ...................................................................................................................................

GM 4.3L LPG ..............................................................................................................................................

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

ELECTRONIC CONTROL VALVE LIFT SECTION - WITH VARIABLE DISPLACEMENT PUMP .....................................................................

OUTLET SECTION - WITH VARIABLE DISPLACEMENT PUMP ..............................................................

TILT SECTION - WITH VARIABLE DISPLACEMENT PUMP .....................................................................

TRANSITION SECTION - WITH VARIABLE DISPLACEMENT PUMP ......................................................

ENGINE AND ATTACHING PARTS KUBOTA 3.8L SI LPG .................................................................................................................................

ENGINE ASSEMBLY ALTERNATOR AND PULLEY - KUBOTA 3.8L SI LPG ..............................................................................

CAMSHAFT AND IDLE GEAR SHAFT - KUBOTA 3.8L SI LPG ................................................................

CYLINDER HEAD - KUBOTA 3.8L SI LPG .................................................................................................

CYLINDER HEAD COVER - KUBOTA 3.8L SI LPG ...................................................................................

DIPSTICK AND GUIDE - KUBOTA 3.8L SI LPG ........................................................................................

ELECTRONIC CONTROL MODULE - KUBOTA 3.8L SI LPG ....................................................................

EXHAUST MANIFOLD - KUBOTA 3.8L SI LPG .........................................................................................

FAN DRIVE AND MOUNTING - KUBOTA 3.8L SI LPG .............................................................................

GEAR CASE - KUBOTA 3.8L SI LPG .........................................................................................................

IGNITION COIL - KUBOTA 3.8L SI LPG ....................................................................................................

INJECTION PUMP COVER - KUBOTA 3.8L SI LPG ..................................................................................

INTAKE MANIFOLD AND THROTTLE BODY - KUBOTA 3.8L SI LPG .....................................................

MAIN BEARING CASE - KUBOTA 3.8L SI LPG .........................................................................................

OIL COOLER - KUBOTA 3.8L SI LPG ........................................................................................................

OIL PAN - KUBOTA 3.8L SI LPG ................................................................................................................

PISTON AND CRANKSHAFT - KUBOTA 3.8L SI LPG ..............................................................................

SHORT BLOCK - KUBOTA 3.8L SI LPG ....................................................................................................

STARTER - KUBOTA 3.8L SI LPG .............................................................................................................

SUPPLY PUMP COVER - KUBOTA 3.8L SI LPG ......................................................................................

THERMOSTAT AND HOUSING - KUBOTA 3.8L SI LPG ...........................................................................

VALVE AND ROCKER ARM - KUBOTA 3.8L SI LPG ................................................................................

WATER PUMP - KUBOTA 3.8L SI LPG .....................................................................................................

ENGINE CONTROL MODULE AND SENSORS GM 4.3L LPG ..............................................................................................................................................

iv

See Service Manual for service procedures.

8-22 8-31 8-28 15-51

2-96 2-95 3-32 3-30 6-4 11-48 11-60 11-52 11-46 4-14 4-44 4-37 4-23 4-22 4-34 4-47 4-33 4-28 4-20 4-41 4-40 4-26 4-36 4-35 4-19 4-38 4-18 4-46 4-42 4-30 4-24 4-32 6-47

©2015 HYSTER COMPANY

01/2016

UNIT CODE U005 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

ENGINE ELECTRICAL SYSTEM GM 4.3L - WITH SEALED ALTERNATOR ..................................................................................................

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

GM 4.3L LPG ..............................................................................................................................................

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

KUBOTA 3.8L DIESEL - WITH STANDARD ALTERNATOR HARNESS ...................................................

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

KUBOTA 3.8L LPG - WITH STANDARD ALTERNATOR HARNESS .........................................................

KUBOTA 3.8L LPG - WITH SEALED ALTERNATOR HARNESS ..............................................................

ENGINE MOUNT .............................................................................................................................................

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

ENGINE WIRE HARNESS AND ATTACHING PARTS KUBOTA 3.6L DIESEL ................................................................................................................................

KUBOTA 3.6L DIESEL - WITH ELECTRONIC THROTTLE .......................................................................

ENGINE WITH ENGINE MOUNT AND TORQUE CONVERTER 3.6L KUBOTA DIESEL ................................................................................................................................

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

E-THROTTLE LINKAGE KUBOTA 3.6L DIESEL ................................................................................................................................

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

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

EXHAUST MANIFOLDS GM 4.3L LPG AND GASOLINE ..................................................................................................................

EXHAUST SYSTEM COUNTERWEIGHT EXHAUST LWB - 3.6L ...............................................................................................

COUNTERWEIGHT EXHAUST LWB - 3.8L WITH DPF .............................................................................

COUNTERWEIGHT EXHAUST SWB - 3.6L ...............................................................................................

COUNTERWEIGHT EXHAUST SWB - 3.8L WITH DPF ............................................................................

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

KUBOTA 3.8L LPG - COUNTERWEIGHT ..................................................................................................

KUBOTA 3.8L LPG - OVERHEAD LONG WHEELBASE ...........................................................................

KUBOTA 3.8L LPG - OVERHEAD SHORT WHEELBASE .........................................................................

OVERHEAD EXHAUST LWB - 3.6L ...........................................................................................................

OVERHEAD EXHAUST LWB - 3.8L WITH DPF .........................................................................................

OVERHEAD EXHAUST SWB - 3.6L ...........................................................................................................

OVERHEAD EXHAUST SWB - 3.8L WITH DPF ........................................................................................

EXHAUST WRAPS GM 4.3L GASOLINE AND LPG ..................................................................................................................

6-48 6-28 6-26 6-24 6-10 6-16 6-18 6-20 6-22 4-16 3-22 6-12 6-14 2-4 2-6 5-24 2-60 2-61 3-37 2-22 2-32 2-26 2-30 3-18 4-8 4-10 4-12 2-24 2-36 2-28 2-34 3-20

F FAN ASSEMBLY GM 4.3L GASOLINE AND LPG .................................................................................................................. 3-26 FAN MOUNT ASSEMBLY GM 4.3L LPG AND GASOLINE .................................................................................................................. 3-24 FAN PULLEY KUBOTA DIESEL - 3.6L, 3.8L ..................................................................................................................... 2-45

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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PAGE

FAN SHROUD WITH RADIATOR SCREEN GASOLINE AND LPG - SHORT WHEEL BASE .........................................................................................

LONG WHEEL BASE - DIESEL ..................................................................................................................

SHORT WHEEL BASE - DIESEL ...............................................................................................................

FAN SHROUD WITHOUT RADIATOR SCREEN GASOLINE AND LPG - SHORT WHEEL BASE .........................................................................................

SHORT WHEEL BASE - DIESEL ...............................................................................................................

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

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

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

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

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

KUBOTA 3.8L LPG .....................................................................................................................................

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

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

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

FORKS WITH LATCH POLISHED FULL BOTTOM TAPER - OPTIONAL EQUIPMENT ...............................................................

STANDARD TAPER - OPTIONAL EQUIPMENT ........................................................................................

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 ..............................................................................................................

TWO 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 PUMP AND SENDER GM 4.3L GASOLINE ...................................................................................................................................

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

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

FUEL SYSTEM 3.8L LPG - WITH LOW FUEL SENSOR .....................................................................................................

3.8L LPG - W/O LOW FUEL SENSOR .......................................................................................................

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

vi

See Service Manual for service procedures.

3-17 2-20 2-19 3-16 2-18 1-78 15-52 1-74 1-76 3-28 4-17 2-44 1-86 1-84 1-89 1-87 7-16 7-30 7-28 14-24 13-18 5-30 2-102 2-91 2-101 5-34 2-92 5-28 5-44 5-46 5-31

©2015 HYSTER COMPANY

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

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

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 .........................................................

G GEAR CASE KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

GEAR PUMP ...................................................................................................................................................

GOVERNOR KUBOTA DIESEL - 3.6L ..............................................................................................................................

GOVERNOR ACTUATOR AND PLUG KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

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

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

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

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

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

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

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

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

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

THREE STAGE FULL FREE- LIFT - INTEGRAL SIDE-SHIFT CARRIAGE WITHOUT QUICK DISCONNECTS ..........................................................................................................................................

THREE STAGE FULL FREE- LIFT - ATTACHMENT CARRIAGE WITHOUT QUICK DISCONNECTS ....

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

TWO STAGE FULL FREE- LIFT - INTEGRAL SIDE-SHIFT CARRIAGE WITHOUT QUICK DISCONNECTS ..........................................................................................................................................

TWO STAGE FULL FREE- LIFT - ATTACHMENT CARRIAGE WITHOUT QUICK DISCONNECTS ........

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

TWO STAGE LIMITED FREE-LIFT - INTEGRAL SIDE-SHIFT CARRIAGE WITHOUT QUICK DISCONNECTS ..........................................................................................................................................

TWO STAGE LIMITED FREE-LIFT - ATTACHMENT CARRIAGE WITHOUT QUICK DISCONNECTS ....................................................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

5-36 5-26 1-64 1-58 1-60 1-62

2-62 2-64 11-14 2-104 2-106

11-22 11-24 11-18 11-20 14-28 13-22 12-14 15-24 15-32 15-20 15-30 15-16 15-28 14-32 15-8 15-14 13-26 15-7 15-12 12-16 15-6 15-10

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HEATER HOSES GM 4.3L GASOLINE ...................................................................................................................................

GM 4.3L LPG ..............................................................................................................................................

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

KUBOTA LPG .............................................................................................................................................

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

HOSE GROUPS HYDRAULIC CONTROL VALVE (MANUAL) AUXILIARY ONE AND TWO SECTION - THREE AND FOUR FUNCTION ...............................................

LIFT AND TILT - THREE AND FOUR FUNCTION .....................................................................................

OUTLET SECTION - THREE AND FOUR FUNCTION ..............................................................................

THREE AND FOUR FUNCTION .................................................................................................................

HYDRAULIC FAN DRIVE 4.3L GASOLINE AND LPG - LWB ..............................................................................................................

4.3L GASOLINE AND LPG - SWB ..............................................................................................................

KUBOTA 3.8L DIESEL/LPG - LWB .............................................................................................................

KUBOTA 3.8L DIESEL/LPG - SWB ............................................................................................................

WITH VARIABLE DISPLACEMENT PUMP ................................................................................................

HYDRAULIC FAN DRIVE MANIFOLD ............................................................................................................

HYDRAULIC FILTER ......................................................................................................................................

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

WITH VARIABLE DISPLACEMENT PUMP ................................................................................................

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

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

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

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

INJECTOR BODY KUBOTA 3.6L DIESEL ................................................................................................................................

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

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

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

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

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

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

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

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

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

viii

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1-50 1-48 1-53 1-52 1-72 11-34 11-32 11-36 11-30 3-4 3-6 2-8 2-10 11-8 11-10 11-12 11-2 11-4 6-56 2-93 2-98 2-97 2-100 2-94 2-55 2-56 2-58 14-10 14-12 6-58 3-50 15-46

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

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

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

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

15-42 15-38 15-34

L LABELS CONTROL LEVER LENS - MANUAL HYDRAULICS .................................................................................

EXTERIOR ..................................................................................................................................................

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 BACKREST EXTENSION .....................................................................................................................

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

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

LPG LOCK OFF GM 4.3L .......................................................................................................................................................

LPG REGULATOR AND MIXER GM 4.3L .......................................................................................................................................................

LPG TANK BRACKET SWING OUT ................................................................................................................................................

SWING OUT, DROP DOWN .......................................................................................................................

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

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

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

TWO STAGE FULL FREE LIFT - H100-120FT ...........................................................................................

TWO STAGE LIMITED FREE LIFT - H80-90FT .........................................................................................

TWO STAGE LIMITED FREE LIFT - H100-120FT .....................................................................................

MANUAL HYDRAULIC CONTROLS AND CONTROL VALVES .....................................................................

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

TWO STAGE FULL FREE LIFT - INNER MAST AND FREE LIFT .............................................................

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

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

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

MINI LEVER MODULE LABELS ELECTRO-HYDRAULIC CONTROL FUNCTIONS .....................................................................................

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

14-6

1-96 1-92 1-94 15-54 6-64 6-66 1-82 6-62 5-41 5-42 5-40 5-48 5-50

14-16 14-20 13-10 13-14 12-10 12-12 16-7 13-2 13-6 12-2 12-6 6-59 1-98 6-68 6-70

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PAGE

MINI-LEVER HYDRAULIC CONTROLS AND CONTROL VALVES ............................................................... 16-6 MIRROR WITHOUT CAB ........................................................................................................................................... 15-50 MUD GUARDS ................................................................................................................................................ 1-80 N NON SUSPENSION SEAT WITHOUT ELECTRONIC CONTROLS ...................................................................................................... 1-54 NOZZLE HOLDER AND GLOW PLUG KUBOTA DIESEL - 3.6L .............................................................................................................................. 2-99 O OIL COOLER KUBOTA DIESEL - 3.6L ..............................................................................................................................

KUBOTA DIESEL - 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 ..............................................................................................................

OVERHEAD GUARD ......................................................................................................................................

P PARK BRAKE ASSEMBLY MANUAL WITH ONE CABLE - NMHG .......................................................................................................

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 ..................................................................................................................

R RADIATOR ASSEMBLY GM 4.3L - WITH EXTERNAL OIL COOLER ...............................................................................................

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

KUBOTA 3.8L LPG .....................................................................................................................................

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

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

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

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

x

See Service Manual for service procedures.

2-82 2-83 2-77 3-54 2-87 14-2 1-6

10-18 10-16 2-70 2-72 6-50 5-15 5-16 3-34

3-14 2-14 4-6 15-2 16-6 6-52 6-60

©2015 HYSTER COMPANY

01/2016

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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 BELT SWITCH ADAPTER ....................................................................................................................

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

SENSORS KUBOTA DIESEL - 3.8L ..............................................................................................................................

SOUND ABATEMENT WITH CAB ...................................................................................................................................................

SPARK PLUGS AND WIRES GM 4.3L GASOLINE AND LPG ..................................................................................................................

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

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

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

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

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

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

STEERING COLUMN AND ATTACHING PARTS ..........................................................................................

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

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

STEERING CONTROL UNIT ..........................................................................................................................

STEERING HOSES .........................................................................................................................................

STROBE LIGHT LED .............................................................................................................................................................

SWIVEL SEATS ..............................................................................................................................................

T THERMOSTAT AND WATER OUTLET HOUSING GM 4.3L LPG ..............................................................................................................................................

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

THROTTLE BODY GM 4.3L - GASOLINE .................................................................................................................................

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

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

THROTTLE PEDAL ASSEMBLY AND ATTACHING PARTS MONOTROL PEDAL ...................................................................................................................................

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

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

7-32 7-18 2-52 2-54 6-61 1-56 2-108 1-90 6-53 16-2 6-54 2-109 9-12 9-16 9-18 9-2 9-6 9-4 9-8 9-10 15-4 16-2

3-38 3-39 5-38 5-39 5-22 5-20 5-18 11-68 11-70

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

KUBOTA 3.8L LPG .....................................................................................................................................

TRANSMISSION DUAL SPEED - SHEET 1 OF 3 ..................................................................................................................

DUAL SPEED - SHEET 2 OF 3 ..................................................................................................................

DUAL SPEED - SHEET 3 OF 3 ..................................................................................................................

SINGLE SPEED - SHEET 1 OF 3 ...............................................................................................................

SINGLE SPEED - SHEET 2 OF 3 ...............................................................................................................

SINGLE SPEED - SHEET 3 OF 3 ...............................................................................................................

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

TRANSMISSION COOLING LINES WITH EXTERNAL OIL COOLER - GASOLINE, LPG AND DIESEL ...........................................................

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

WITHOUT EXTERNAL OIL COOLER - GASOLINE AND LPG ..................................................................

TRANSMISSION HARNESS GROUP WITH AND WITHOUT BRAKE TEMP .........................................................................................................

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 ..............................................................................................................................

11-72

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

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

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

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

OUTLET SECTION - ELECTRONIC CONTROL VALVE-THREE AND FOUR FUNCTION .......................

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

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

VARIABLE DISPLACEMENT PUMP ASSEMBLY .................................................................................................................................................

VARIABLE DISPLACEMENT PUMP AND ADAPTOR ....................................................................................

VENT LINE GROUP WITH STANDARD CONTROL VALVE .......................................................................................................

WITH VARIABLE DISPLACEMENT CONTROL VALVE ............................................................................

7-8 7-9 7-20 7-22 7-24 7-11 7-12 7-14 7-34 7-6 7-2 7-4 6-72 7-10 2-88 2-84 2-85 2-89 2-90

11-54 11-56 11-62 11-44 11-58 11-50 3-48 11-17 11-16 11-66 11-67

W WATER BYPASS GM 4.3L GASOLINE ................................................................................................................................... 3-56

xii

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©2015 HYSTER COMPANY

01/2016

UNIT CODE U005 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

WATER PUMP KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

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

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

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

WET BRAKE BOOSTER SUPPLY AND RETURN NMHG .........................................................................................................................................................

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

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

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

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

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

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

COWL - MANUAL HYDRAULICS WITH MONOTROL PEDAL ..................................................................

COWL - MANUAL HYDRAULICS WITH FORWARD/REVERSE ...............................................................

COWL - ELECTRO-HYDRAULICS WITH MONOTROL PEDAL ................................................................

COWL - ELECTRO-HYDRAULICS WITH FORWARD/REVERSE .............................................................

DPF DISPLAY .............................................................................................................................................

ENGINE - GM 4.3L LPG .............................................................................................................................

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

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

ENGINE - KUBOTA 3.8L SI LPG ................................................................................................................

ENGINE WITH ELECTRONIC THROTTLE - KUBOTA DIESEL 3.6L ........................................................

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

RH CHASSIS - GM 4.3L GAS/LPG AND KUBOTA 3.8L DIESEL/LPG ......................................................

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

RH CHASSIS WITH SEAT BELT SEQUENCE MODULE - GM 4.3L GAS/LPG AND KUBOTA 3.8L DIESEL/ LPG .............................................................................................................................................................

RH CHASSIS WITH SEAT BELT SEQUENCE MODULE - KUBOTA DIESEL (3.6L) ................................

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

SEALED ALTERNATOR - KUBOTA 3.8L LPG ...........................................................................................

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

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

TRANSMISSION WITH BRAKE TEMP - SINGLE SPEED .........................................................................

TRANSMISSION WITH BRAKE TEMP - TWO SPEED ..............................................................................

TYPE S ALTERNATOR ..............................................................................................................................

WIRE HARNESS FOUR FUNCTION ELECTRONIC CONTROL VALVE - WITH VARIABLE DISPLACEMENT PUMP .......................................

WIRE HARNESS THREE FUNCTION ELECTRONIC CONTROL VALVE - WITH VARIABLE DISPLACEMENT PUMP .......................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-79 2-81 2-78 2-80 8-26 10-12 16-2 6-73 6-74 6-147 6-149 6-142 6-124 6-128 6-132 6-136 6-156 6-78 6-82 6-88 6-92 6-96 6-140 6-100 6-112 6-106 6-118 6-144 6-146 6-158 6-162 6-166 6-170 6-154 6-152 6-150

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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

xiv

See Service Manual for service procedures.

©2015 HYSTER COMPANY

01/2016

UNIT CODE U005 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.

xv