Hyster E80XN E90XN E100XN E100XNS E120XN (A099) Parts Manual – PDF DOWNLOAD

Description

Hyster E80XN E90XN E100XN E100XNS E120XN (A099) Parts Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster E80XN E90XN E100XN E100XNS E120XN (A099) Parts Manual – PDF DOWNLOAD

HOW TO USE THE ILLUSTRATED PARTS MANUAL:

This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement. The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

HOW TO FIND THE DESIRED PART NUMBER
WHEN THE PART NUMBER AND THE NEXT
HIGHER ASSEMBLY IS NOT KNOWN:
1. 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.
2. 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:
3. Determine the assembly the required part is used
on. Turn to the Table of Contents (Page i).
4. 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.

TABLE OF CONTENTS:

Hyster E80XN E90XN E100XN E100XNS E120XN (A099) Parts Manual – PDF DOWNLOAD

Frame............................................................................................................ 19
	OPERATOR MODULE.............................................................................................. 22
	COUNTERWEIGHT................................................................................................ 24
	COUNTERWEIGHT COVER WITH RAPID CHARGE OPTION................................................................. 25
	OVERHEAD GUARD STANDARD...................................................................................... 26
	OVERHEAD GUARD FLAT.......................................................................................... 28
	FLOORPLATES AND STEPS........................................................................................ 30
	FENDERS...................................................................................................... 32
	DRIP SHIELD AND STATIC STRAP................................................................................. 33
	HOOD WITH STANDARD OVERHEAD GUARD - E100XNS ................................................................. 34
	HOOD WITH STANDARD OVERHEAD GUARD - E80-E120XN .............................................................. 36
	HOOD WITH FLAT OVERHEAD GUARD - E100XNS ..................................................................... 38
	HOOD WITH FLAT OVERHEAD GUARD - E80-E120XN .................................................................. 40
	SEATS NON SUSPENSION - WITH HIP RESTRAINTS .................................................................. 42
	SEATS NON SUSPENSION - LOW PROFILE WITH HIP RESTRAINTS ...................................................... 44
	SEATS FULL SUSPENSION - SHEET 1 0F 2 ........................................................................ 46
	SEATS FULL SUSPENSION - SHEET 2 OF 2 ........................................................................ 50
	ARMREST SLIDER ASSEMBLY...................................................................................... 52
	BATTERY COMPARTMENT AND COVERS HORIZONTAL BATTERY REMOVAL  (→ 4/2013) ....................................... 54
	BATTERY COMPARTMENT AND COVERS HORIZONTAL BATTERY REMOVAL  (4/2013 →) ....................................... 58
	BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL - E80-120XN   (→ 4/2013) ............................ 62
	BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL - E80-120XN   (4/2013 →) ............................ 64
	BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL - E100XNS WITH STANDARD OVERHEAD GUARD .............. 66
	BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL - E100XNS WITH FLAT OVERHEAD GUARD   (→ 4/2013) ..... 68
	BATTERY COMPARTMENT AND COVERS VERTICAL BATTERY REMOVAL - E100XNS WITH FLAT OVERHEAD GUARD   (4/2013 →) ..... 70
	DASH AND STEERING COLUMN COVERS FIXED COLUMN................................................................. 72
	DASH AND STEERING COLUMN COVERS TELESCOPIC COLUMN............................................................ 74
	FORKS STANDARD TAPER CLASS III AND CLASS IV.................................................................. 76
	FORKS POLISHED FORK WITH FULL BOTTOM TAPER - CLASS III AND CLASS IV ......................................... 78
	FORKS OPTIONAL LATCH......................................................................................... 79
	FORKS WITH LATCH STANDARD TAPER OPTIONAL - CLASS III AND CLASS IV ........................................... 80
	FORKS POLISHED FULL BOTTOM  TAPER OPTIONAL - CLASS III AND CLASS IV ......................................... 82
	LOAD BACKREST EXTENSION...................................................................................... 84
	NAMEPLATES AND LABELS SHEET 1 OF 2........................................................................... 86
	NAMEPLATES AND LABELS SHEET 2 OF 2........................................................................... 88
	NAMEPLATES AND LABELS HYDRAULIC CONTROL FUNCTIONS............................................................ 90
ELECTRICAL SYSTEM................................................................................................ 93
	ELECTRICAL ARRANGEMENT....................................................................................... 98
	BATTERY CONNECTOR WITH STANDARD OVERHEAD GUARD - LWB (E80-120XN) ............................................100
	BATTERY CONNECTOR WITH STANDARD OVERHEAD GUARD - SWB (E100XNS) ..............................................102
	BATTERY CONNECTOR WITH FLAT OVERHEAD GUARD - LWB (E80-120XN) ................................................103
	BATTERY CONNECTOR WITH FLAT OVERHEAD GUARD - SWB (E100XNS) ..................................................105
	BATTERY CONNECTOR RAPID CHARGE OPTION........................................................................107
	CONTROL PANELS AND CONTACTORS................................................................................108
	CONTACTOR AND FUSE ASSEMBLY..................................................................................109
	CONTACTOR ASSEMBLY UL-E......................................................................................110
	CONTACTOR ASSEMBLY UL-EE.....................................................................................112
	CONTROLLER ASSEMBLY PUMP MOTOR...............................................................................114
	CONTROLLER ASSEMBLY TRACTION MOTOR...........................................................................116
	DISPLAY GROUP AND HARNESS HIGH MOUNT.........................................................................118
	DISPLAY LOW MOUNT............................................................................................120
	LIGHTS.......................................................................................................122
	MINI-LEVER CONTROLS 3 FUNCTION...............................................................................126
	MINI-LEVER CONTROLS 4 FUNCTION...............................................................................128
	POWER CABLES E80-E120XN......................................................................................130
	POWER CABLES E100XNS.........................................................................................132
	TILT SENSOR GROUP............................................................................................134
	VEHICLE SYSTEM MANAGER.......................................................................................135
	WIRE HARNESS RH LIGHTS - STANDARD OPTION   (→ 10/2013) ......................................................136
	WIRE HARNESS RH LIGHT WITH STANDARD DISPLAY - WITHOUT TURN SIGNALS-HIGH MOUNT   (10/2013 →) .................137
	WIRE HARNESS RH LIGHT WITH STANDARD DISPLAY - WITHOUT TURN SIGNALS-LOW MOUNT   (10/2013 →) ..................138
	WIRE HARNESS RH LIGHTS - FREEZER OPTION   (→ 10/2013) .......................................................140
	WIRE HARNESS RH LIGHT WITH FREEZER DISPLAY - WITH TURN SIGNALS-HIGH MOUNT   (10/2013 →) .....................142
	WIRE HARNESS RH LIGHT WITH FREEZER DISPLAY - WITH TURN SIGNALS-LOW MOUNT   (10/2013 →) ......................143
	WIRE HARNESS EMERGENCY DISCONNECT............................................................................144
	WIRE HARNESS FRONT SWITCH....................................................................................145
	WIRE HARNESS LIGHTS - LEFT HAND .............................................................................146
	WIRE HARNESS MAIN - MANUAL HYDRAULIC SHEET 1 OF 3 ...........................................................148
	WIRE HARNESS MAIN - MANUAL HYDRAULIC SHEET 2 OF 3 ...........................................................152
	WIRE HARNESS MAIN - MANUAL HYDRAULIC SHEET 3 OF 3 ...........................................................156
	WIRE HARNESS MAIN - ELECTRO-HYDRAULIC SHEET 1 OF 3 ..........................................................160
	WIRE HARNESS MAIN - ELECTRO-HYDRAULIC SHEET 2 OF 3 ..........................................................164
	WIRE HARNESS MAIN - ELECTRO-HYDRAULIC SHEET 3 OF 3 ..........................................................168
	WIRE HARNESS MAIN LIGHTS CHASSIS - 48V ......................................................................172
	WIRE HARNESS MAIN LIGHTS CHASSIS - 80V ......................................................................176
	WIRE HARNESS MAIN CHASSIS - W/O LIGHTS ......................................................................180
	WIRE HARNESS MANUAL INTERLOCK................................................................................182
	WIRE HARNESS SEAT - MANUAL HYDRAULIC ........................................................................183
	WIRE HARNESS SEAT - E-HYDRAULIC .............................................................................184
	WIRE HARNESS STEERING COLUMN.................................................................................186
	WIRE HARNESS SYNCHRONOUS STEERING............................................................................188
	WIRE HARNESS JUMPER..........................................................................................189
DRIVE UNIT.......................................................................................................191
	DRIVE AXLE AND ATTACHING PARTS...............................................................................194
	DRIVE AXLE ASSEMBLY WET BRAKE - RIGHT AND LEFT HAND HUBS ....................................................196
	DRIVE AXLE ASSEMBLY WET BRAKE - BRAKES AND DIFFERENTIAL .....................................................200
	DRIVE AXLE ASSEMBLY WET BRAKE - INPUT PINION CARRIER ........................................................203
	DIFFERENTIAL ASSEMBLY WET BRAKE..............................................................................205
	TRACTION MOTOR...............................................................................................206
	DRIVE TIRE AND WHEEL E80XN...................................................................................207
	DRIVE TIRE AND WHEEL E100-120XN/E100XNS......................................................................208
STEERING SYSTEM..................................................................................................209
	STEER AXLE WITHOUT SYNCHRONUS STEERING OPTION................................................................212
	STEER AXLE WITH SYNCHRONUS STEERING OPTION...................................................................216
	STEER AXLE CYLINDER..........................................................................................220
	STEERING ACCUMULATOR.........................................................................................222
	STEER TIRE AND WHEEL.........................................................................................223
	STEERING WHEEL AND COLUMN FIXED..............................................................................224
	STEERING WHEEL AND COLUMN TELESCOPIC.........................................................................225
	STEERING COLUMN ASSEMBLY FIXED  (→ 10/2013) .................................................................226
	STEERING COLUMN ASSEMBLY FIXED  (10/2013 →) .................................................................228
	STEERING COLUMN ASSEMBLY TELESCOPIC  (→ 10/2013) ............................................................230
	STEERING COLUMN ASSEMBLY TELESCOPIC  (10/2013 →) ............................................................231
	STEER PUMP ASSEMBLY..........................................................................................232
BRAKE/ACCELERATOR SYSTEM.........................................................................................235
	BRAKE SYSTEM.................................................................................................238
	BRAKE ASSEMBLY...............................................................................................240
	PARKING BRAKE VALVE..........................................................................................242
	MASTER CYLINDER..............................................................................................243
	ACCELERATOR PEDAL ASSEMBLY (STANDARD)........................................................................244
	ACCELERATOR PEDAL ASSEMBLY (MONOTROL)........................................................................245
HYDRAULIC SYSTEM.................................................................................................247
	HYDRAULIC SUPPLY AND RETURN..................................................................................250
	HYDRAULIC TANK AND ATTACHING PARTS...........................................................................254
	HYDRAULIC HOSES STEERING.....................................................................................256
	HYDRAULIC PUMP AND  MOTOR MOUNTING...........................................................................258
	HYDRAULIC PUMP 33 cc.........................................................................................260
	HYDRAULIC MOTOR ASSEMBLY.....................................................................................262
	MANUAL CONTROL LEVERS........................................................................................264
	HYDRAULIC CONTROL VALVE AND FITTINGS MANUAL HYDRAULIC - THREE AND FOUR FUNCTION .............................267
	HYDRAULIC CONTROL VALVE ASSEMBLY MANUAL HYDRAULIC - THREE AND FOUR FUNCTION .................................268
	HYDRAULIC CONTROL VALVE LIFT, TILT, AND AUXILIARY - MANUAL HYDRAULIC ........................................270
	HYDRAULIC CONTROL VALVE INLET SECTION - MANUAL HYDRAULIC ....................................................272
	HYDRAULIC CONTROL VALVE AND FITTINGS ELECTRO-HYDRAULIC - THREE AND FOUR FUNCTION ............................274
	HYDRAULIC CONTROL VALVE ASSEMBLY ELECTRO-HYDRAULIC - THREE AND FOUR FUNCTION ................................276
	HYDRAULIC CONTROL VALVE LIFT, TILT, AND AUXILIARY - ELECTRO-HYDRAULIC .......................................278
	HYDRAULIC CONTROL VALVE INLET SECTION - ELECTRO-HYDRAULIC ...................................................280
	TILT CYLINDER AND ATTACHING PARTS............................................................................282
	TILT CYLINDER................................................................................................284
Mast-Two Stage Limited Free-Lift.................................................................................287
	OUTER MAST TWO STAGE LIMITED FREE-LIFT.......................................................................290
	INNER MAST TWO STAGE LIMITED FREE-LIFT.......................................................................292
	MAIN LIFT TWO STAGE LIMITED FREE-LIFT  (→ PENDING PER ECN 15482601) .........................................294
	MAIN LIFT TWO STAGE LIMITED FREE-LIFT  (PENDING PER ECN 15482601 →) .........................................298
	MAIN LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT - E80XN ......................................................302
	MAIN LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT - E100-120XN/E100XNS .........................................304
	CARRIAGE TWO STAGE LIMITED FREE-LIFT.........................................................................306
	HEADER HOSE TWO STAGE LIMITED FREE-LIFT......................................................................308
Mast-Three Stage Full Free-Lift..................................................................................313
	OUTER MAST THREE STAGE FULL FREE-LIFT  (→ PENDING PER ECN 15482601) .........................................316
	OUTER MAST THREE STAGE FULL FREE-LIFT  (PENDING PER ECN 15482601 →) .........................................320
	INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT.................................................................324
	INNER MAST THREE STAGE FULL FREE-LIFT........................................................................328
	MAIN LIFT THREE STAGE FULL FREE-LIFT.........................................................................332
	MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT................................................................336
	FREE-LIFT THREE STAGE FULL FREE-LIFT  (→ PENDING PER ECN 15482601) ..........................................340
	FREE-LIFT THREE STAGE FULL FREE-LIFT  (PENDING PER ECN 15482601 →) ..........................................344
	FREE-LIFT CYLINDER THREE STAGE FULL FREE LIFT................................................................348
	CARRIAGE THREE STAGE FULL FREE-LIFT..........................................................................352
	HEADER HOSE THREE STAGE FULL FREE-LIFT.......................................................................354
Mast-Two Stage Full Free-Lift....................................................................................361
	OUTER MAST AND MAIN LIFT TWO STAGE FULL FREE-LIFT............................................................364
	INNER MAST AND FREE-LIFT TWO STAGE FULL FREE-LIFT  (→ PENDING PER ECN 15482601) .............................368
	INNER MAST AND FREE-LIFT TWO STAGE FULL FREE-LIFT  (PENDING PER ECN 15482601 →) .............................372
	MAIN LIFT CYLINDER TWO STAGE FULL FREE-LIFT..................................................................376
	FREE-LIFT CYLINDER TWO STAGE FULL FREE-LIFT..................................................................380
	HEADER HOSE TWO STAGE FULL FREE-LIFT.........................................................................384
	CARRIAGE TWO STAGE FULL FREE-LIFT............................................................................390
OPTIONS..........................................................................................................393
	AUXILIARY KEYSWITCH..........................................................................................396
	ACCUMULATOR..................................................................................................398
	BACK-UP ALARM................................................................................................400
	TAIL LIGHT MOUNTING..........................................................................................401
	MIRRORS......................................................................................................402
	MIRROR PANORAMIC.............................................................................................403
	FIRE EXTINGUISHER............................................................................................404
	REAR DRIVE HANDLE............................................................................................405
	IMPACT SENSOR................................................................................................406
	DC CONVERTER AND ATTACHING PARTS.............................................................................408
	INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE LIMITED FREE LIFT CLASS III - ORFS FITTINGS ..........................410
	INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE LIMITED FREE LIFT CLASS IV - ORFS FITTINGS ...........................412
	INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT - 1067 MM (42 IN.) CLASS III .......................414
	INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS III .......................416
	INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS IV ........................418
	INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE FULL FREE-LIFT - E80XN ...............................................420
	INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT - 1067 MM (42 IN.) CLASS III ..........................422
	INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III ..........................424
	INTEGRAL SIDE-SHIFT ASSEMBLY THREE STAGE FULL FREE-LIFT - E80XN .............................................426
	INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III ........................428
	INTEGRAL SIDE-SHIFT ASSEMBLY TWO AND THREE STAGE FULL FREE-LIFT - E100-120XN/E100XNS ........................430
	INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV ...........................432
	INTEGRAL SIDE-SHIFT CARRIAGE 1067 MM (42 IN.) CLASS III - THREE STAGE FULL FREE-LIFT ........................434
	INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV .........................436
	AUXILIARY TUBE EXTENSIONS TWO STAGE LIMITED FREE LIFT - WITHOUT QUICK DISCONNECT FITTINGS ...................438
	AUXILIARY TUBE EXTENSIONS TWO STAGE LIMITED FREE LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ....440
	AUXILIARY TUBE EXTENSIONS TWO STAGE LIMITED FREE LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS .........442
	AUXILIARY TUBE EXTENSIONS THREE  STAGE FULL FREE-LIFT - WITHOUT QUICK DISCONNECT FITTINGS ...................446
	AUXILIARY TUBE EXTENSIONS THREE  STAGE FULL FREE-LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ....448
	AUXILIARY TUBE EXTENSIONS THREE  STAGE FULL FREE-LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS .........450
	AUXILIARY TUBE EXTENSIONS TWO STAGE FULL FREE-LIFT - WITHOUT QUICK DISCONNECT FITTINGS ......................453
	AUXILIARY TUBE EXTENSIONS TWO STAGE FULL FREE- LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ......456
	AUXILIARY TUBE EXTENSIONS TWO STAGE FULL FREE-LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ............458
FIELD CONVERSION KITS............................................................................................461
	CONVERSION KIT HYDRAULICS....................................................................................464
	CONVERSION KIT MISCELLANEOUS.................................................................................464
	CONVERSION KIT BATTERY ROLLERS...............................................................................464
	ADD ON OPTION KITS...........................................................................................464
	ADD ON TELEMETRY KITS SPEEDSHIELD............................................................................465
	ADD ON OPTION KITS BACK-UP ALARM.............................................................................465
	ADD ON OPTION KITS LIGHT KITS................................................................................466
NUMERICAL INDEX..................................................................................................467

HYSTER E80XN E90XN E100XN E100XNS E120XN (A099) PARTS MANUAL – PDF DOWNLOAD:

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