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Hyster FORTIS® S80FT-120FT, S80-100FTBCS, S120FTS, S120FTPRS (G004) Parts Manual – PDF DOWNLOAD
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Description
Hyster FORTIS® S80FT-120FT, S80-100FTBCS, S120FTS, S120FTPRS (G004) Parts Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster FORTIS® S80FT-120FT, S80-100FTBCS, S120FTS, S120FTPRS (G004) Parts Manual – PDF DOWNLOAD
HOW TO USE THE ILLUSTRATED PARTS MANUAL :
- This parts manual describes and illustrates assemblies, sub-assemblies, and detail parts needed for service replacement.
- The different constructions are indicated by keys and footnotes. The call outs 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.
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).
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.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 15-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 15-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
6. Parts Super session Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.
- Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (Figure 10)
7. Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc. Select the appropriate key, “A”, “B”, “C”, “D”, or “E” and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.
TABLE OF CONTENTS:
Hyster FORTIS® S80FT-120FT, S80-100FTBCS, S120FTS, S120FTPRS (G004) Parts Manual – PDF DOWNLOAD
Frame..................................................................................................................................................................................................................................................................................................................................... 21 HOOD.................................................................................................................................................................................................................................................................................................................................. 24 FLOORPLATES AND COVERS................................................................................................................................................................................................................................................................................................................ 26 FLOORPLATES AND COVERS................................................................................................................................................................................................................................................................................................................ 30 COWL MOUNT............................................................................................................................................................................................................................................................................................................................ 33 COUNTERWEIGHT......................................................................................................................................................................................................................................................................................................................... 36 OVERHEAD GUARD........................................................................................................................................................................................................................................................................................................................ 38 NON-SUSPENSION SEAT................................................................................................................................................................................................................................................................................................................... 40 SEMI-SUSPENSION SEAT WITH AND WITHOUT ELECTRONIC CONTROLS (→ 7/2006) ................................................................................................................................................................................................................................................................ 42 SEMI-SUSPENSION SEAT WITH AND WITHOUT ELECTRONIC CONTROLS (7/2006 →) ................................................................................................................................................................................................................................................................ 44 FULL SUSPENSION SEAT WITH AND WITHOUT ELECTRONIC CONTROLS............................................................................................................................................................................................................................................................................. 48 FULL SUSPENSION SWIVEL SEAT WITH AND WITHOUT ELECTRONIC CONTROLS...................................................................................................................................................................................................................................................................... 50 FORK STANDARD TAPER HOOK TYPE - CLASS III ............................................................................................................................................................................................................................................................................................ 52 FORK STANDARD TAPER HOOK TYPE - CLASS IV ............................................................................................................................................................................................................................................................................................. 53 FORK POLISHED WITH FULL BOTTOM TAPER HOOK TYPE........................................................................................................................................................................................................................................................................................ 54 LOAD BACKREST EXTENSION............................................................................................................................................................................................................................................................................................................... 56 ELECTRONIC MINI LEVER LABELS AUXILIARY SINGLE FUNCTION................................................................................................................................................................................................................................................................................ 58 ELECTRONIC MINI LEVER LABELS AUXILIARY DUAL FUNCTION.................................................................................................................................................................................................................................................................................. 60 JOYSTICK CONTROL LABELS............................................................................................................................................................................................................................................................................................................... 62 JOYSTICK CONTROL LABELS WITH RETURN TO SET TILT....................................................................................................................................................................................................................................................................................... 64 CONTROL LEVER LABELS.................................................................................................................................................................................................................................................................................................................. 66 LABELS INTERIOR....................................................................................................................................................................................................................................................................................................................... 68 LABELS EXTERIOR....................................................................................................................................................................................................................................................................................................................... 70 ENGINES................................................................................................................................................................................................................................................................................................................................... 73 ENGINE ASSEMBLY GM 4.3L, GASOLINE AND LPG - SHEET 1 OF 3 ............................................................................................................................................................................................................................................................................. 76 ENGINE ASSEMBLY GM 4.3L, GASOLINE AND LPG - SHEET 2 OF 3 ............................................................................................................................................................................................................................................................................. 80 ENGINE ASSEMBLY GM 4.3L, GASOLINE AND LPG - SHEET 3 OF 3 ............................................................................................................................................................................................................................................................................. 84 ENGINE MOUNT GM 4.3L, GASOLINE AND LPG................................................................................................................................................................................................................................................................................................ 86 EXHAUST SYSTEM GM 4.3L, GASOLINE AND LPG - WITH CATALYTIC CONVERTER .................................................................................................................................................................................................................................................................. 88 EXHAUST WRAPS GM 4.3L, GASOLINE AND LPG............................................................................................................................................................................................................................................................................................... 92 ENGINE COOLING SYSTEM WITH BASIC TRANSMISSION AND DRY BRAKES (→ 11/2006) ............................................................................................................................................................................................................................................................ 94 ENGINE COOLING SYSTEM WITH BASIC TRANSMISSION AND DRY BRAKES (11/2006 →) ............................................................................................................................................................................................................................................................ 98 ENGINE COOLING SYSTEM WITH EXTERNAL OIL COOLER AND WITH ELECTRONIC TRANSMISSION - OR WITH WET BRAKES (→ 11/2006) ...................................................................................................................................................................................................................102 ENGINE COOLING SYSTEM WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION - OR WITH WET BRAKES (11/2006 →) ........................................................................................................................................................................................................................106 FAN ASSEMBLY..........................................................................................................................................................................................................................................................................................................................109 FAN MOUNT ASSEMBLY GM 4.3L, GASOLINE AND LPG..........................................................................................................................................................................................................................................................................................110 FLYWHEEL AND HOUSING GM 4.3L, GASOLINE AND LPG (→ S/N G004V02834E (ONE SPEED WITH WET BRAKE)) (→ S/N G004V02844E INC. 02874-02877, 02879-02880, 02882-02883, 02891, 02894-02896, 02898, 02901-02902 (ONE SPEED WITH DRY BRAKE)) (→ S/N G004V02842E (TWO SPEED WITH DRY BRAKE)) (→ S/N G004V02844E (TWO SPEED WITH WET BRAKE)) ....112 FLYWHEEL AND HOUSING GM 4.3L, GASOLINE AND LPG (S/N G004V02835E → (ONE SPEED WITH WET BRAKES)) (S/N G004V02845E → EXC. 02874-02877, 02879-02880, 02882-02883, 02891, 00289 (ONE SPEED WITH DRY BRAKE)) (S/N G004V00284E → (TWO SPEED WITH DRY BRAKE)) (S/N G004V02847E → (TWO SPEED WITH WET BRAKE)) .............................116 CYLINDER HEAD GM 4.3L, GASOLINE AND LPG...............................................................................................................................................................................................................................................................................................120 CYLINDER BLOCK GM 4.3L, GASOLINE AND LPG..............................................................................................................................................................................................................................................................................................122 CAMSHAFT AND OIL PAN GM 4.3L, GASOLINE AND LPG........................................................................................................................................................................................................................................................................................124 COIL ASSEMBLY GM 4.3L, GASOLINE AND LPG...............................................................................................................................................................................................................................................................................................127 OIL PUMP GM 4.3L, GASOLINE AND LPG....................................................................................................................................................................................................................................................................................................128 VALVE COVER AND INLET MANIFOLD GM 4.3L, GASOLINE AND LPG..............................................................................................................................................................................................................................................................................130 FUEL SYSTEM...............................................................................................................................................................................................................................................................................................................................133 FUEL SYSTEM GM 4.3L, GASOLINE.........................................................................................................................................................................................................................................................................................................136 FUEL SYSTEM GM 4.3L, LPG..............................................................................................................................................................................................................................................................................................................138 AIR CLEANER GM 4.3L - GASOLINE AND LPG (→ S/N G004V03075E) .........................................................................................................................................................................................................................................................................142 AIR CLEANER GM 4.3L - GASOLINE AND LPG (S/N G004V03076E →) .........................................................................................................................................................................................................................................................................144 PRE-CLEANER AND MOUNT.................................................................................................................................................................................................................................................................................................................146 AIR FILTER............................................................................................................................................................................................................................................................................................................................147 REGULATOR LPG.........................................................................................................................................................................................................................................................................................................................148 LPG TANK BRACKET SWING OUT (→ S/N G004V03216F) (→ S/N G004V03117E (Box Car Special)) ...............................................................................................................................................................................................................................................150 LPG TANK BRACKET SWING OUT (S/N G004V03217F →) (S/N G004V03118E → (Box Car Special)) ...............................................................................................................................................................................................................................................152 LPG TANK BRACKET SWING OUT/ DROP DOWN (→ S/N G004V03038E) (→ S/N G004V03035E (Box Car Special)) ....................................................................................................................................................................................................................................154 LPG TANK BRACKET SWING OUT/DROP DOWN (S/N G004V03039E →) (S/N G004V03036E → (Box Car Special)) .....................................................................................................................................................................................................................................158 THROTTLE BODY ASSEMBLY AND FUEL RAIL GM 4.3L, GASOLINE................................................................................................................................................................................................................................................................................162 THROTTLE BODY ASSEMBLY GM 4.3L, LPG...................................................................................................................................................................................................................................................................................................164 THROTTLE PEDAL AND ATTACHING PARTS....................................................................................................................................................................................................................................................................................................166 MONOTROL PEDAL ASSEMBLY...............................................................................................................................................................................................................................................................................................................168 ELECTRICAL SYSTEM.........................................................................................................................................................................................................................................................................................................................171 ELECTRICAL SYSTEM RIGHT HAND CHASSIS..................................................................................................................................................................................................................................................................................................176 ELECTRICAL SYSTEM ENGINE, GM 4.3L, GASOLINE AND LPG...................................................................................................................................................................................................................................................................................178 ELECTRICAL SYSTEM ENGINE, GM 4.3L, GS AND LPS.........................................................................................................................................................................................................................................................................................180 ELECTRICAL SYSTEM COWL................................................................................................................................................................................................................................................................................................................184 ELECTRICAL SYSTEM COWL, ELECTRONIC HYDRAULIC - WITH OPERATOR PRESENCE SYSTEM .........................................................................................................................................................................................................................................................186 ELECTRICAL SYSTEM COWL, MANUAL HYDRAULIC - WITH OPERATOR PRESENCE SYSTEM .............................................................................................................................................................................................................................................................188 ELECTRICAL SYSTEM TRANSMISSION........................................................................................................................................................................................................................................................................................................190 ELECTRICAL SYSTEM MAST................................................................................................................................................................................................................................................................................................................192 ELECTRICAL SYSTEM LOAD WEIGH..........................................................................................................................................................................................................................................................................................................194 POWER DISTRIBUTION MODULE.............................................................................................................................................................................................................................................................................................................196 POWER DISTRIBUTION MODULE.............................................................................................................................................................................................................................................................................................................197 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULES - DATE CODE 0724 ........................................................................................................................................................................................................................................................................198 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0725 THROUGH 0743 ..........................................................................................................................................................................................................................................200 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) - DATE CODE 0725 THROUGH 0743 ...................................................................................................................................................................................................................................202 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULES (THREE FUNCTION) - DATE CODE 0744 .......................................................................................................................................................................................................................................................206 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULE (FOUR AND FIVE FUNCTION) - DATE CODE 0744 ................................................................................................................................................................................................................................................210 JOYSTICK..............................................................................................................................................................................................................................................................................................................................214 REMOTE KEY SWITCH.....................................................................................................................................................................................................................................................................................................................216 SEALED ALTERNATOR AND MOUNTING GM 4.3L................................................................................................................................................................................................................................................................................................217 STARTER GM 4.3L, GS AND LPS (PENDING PER ECN 105844 →) ..............................................................................................................................................................................................................................................................................218 DISTRIBUTOR ASSEMBLY..................................................................................................................................................................................................................................................................................................................220 INSTRUMENT CLUSTER....................................................................................................................................................................................................................................................................................................................221 WORK, REAR DRIVE, AND BRAKE/TAIL LIGHTS...............................................................................................................................................................................................................................................................................................222 IMPACT SENSOR.........................................................................................................................................................................................................................................................................................................................224 WIRE HARNESS RIGHT HAND CHASSIS - GM 4.3L (→ 8/2006) ...............................................................................................................................................................................................................................................................................226 WIRE HARNESS RIGHT HAND CHASSIS - GM 4.3L (8/2006 ↔ S/N G004V02853E (LPG)) (8/2006 ↔ S/N G004V03165E (Gasoline)) ..................................................................................................................................................................................................................232 WIRE HARNESS RIGHT HAND CHASSIS - GM 4.3L (S/N G004V02854E ↔ S/N G004V04328G (LPG)) (S/N G004V03166E ↔ S/N G004V04328G (Gasoline)) ................................................................................................................................................................................................238 WIRE HARNESS RIGHT HAND CHASSIS - GM 4.3L (S/N G004V04329G →) ......................................................................................................................................................................................................................................................................244 WIRE HARNESS LEFT HAND CHASSIS - GM 4.3L, GASOLINE ...................................................................................................................................................................................................................................................................................250 WIRE HARNESS LEFT HAND CHASSIS - GM 4.3L, LPG ........................................................................................................................................................................................................................................................................................252 WIRE HARNESS ENGINE - GM 4.3L, GASOLINE (→ S/N G004V03165E) ........................................................................................................................................................................................................................................................................254 WIRE HARNESS ENGINE - GM 4.3L, GASOLINE (S/N G004V03166E →) ........................................................................................................................................................................................................................................................................256 WIRE HARNESS ENGINE - GM 4.3L, LPG (→ S/N G004V02853E) .............................................................................................................................................................................................................................................................................260 WIRE HARNESS ENGINE - GM 4.3L, LPG (S/N G004V02854E →) .............................................................................................................................................................................................................................................................................262 WIRE HARNESS SEALED ALTERNATOR - GM 4.3L .............................................................................................................................................................................................................................................................................................265 WIRE HARNESS COWL WITH FORWARD/REVERSE LEVER - MANUAL, WITH OPERATOR PRESENCE ........................................................................................................................................................................................................................................................268 WIRE HARNESS COWL WITH FORWARD/REVERSE LEVER - WITHOUT RETURN TO SET TILT ............................................................................................................................................................................................................................................................272 WIRE HARNESS COWL WITH MONOTROL PEDAL - WITH RETURN TO SET TILT ......................................................................................................................................................................................................................................................................276 WIRE HARNESS COWL WITH MONOTROL PEDAL - WITH HYDRAULIC PUMP SOLENOID .................................................................................................................................................................................................................................................................280 WIRE HARNESS ELECTRONIC CONTROL VALVE - THREE FUNCTION ...............................................................................................................................................................................................................................................................................284 WIRE HARNESS ELECTRONIC CONTROL VALVE - FOUR FUNCTION ................................................................................................................................................................................................................................................................................286 WIRE HARNESS ELECTRONIC CONTROL VALVE - FIVE FUNCTION ................................................................................................................................................................................................................................................................................288 WIRE HARNESS JOYSTICK.................................................................................................................................................................................................................................................................................................................290 WIRE HARNESS TRANSMISSION - SINGLE SPEED .............................................................................................................................................................................................................................................................................................292 WIRE HARNESS TRANSMISSION - DUAL SPEED ...............................................................................................................................................................................................................................................................................................294 WIRE HARNESS LIGHTS (→ S/N G004V01639D) .............................................................................................................................................................................................................................................................................................296 WIRE HARNESS LIGHTS (S/N G004V01640D ↔ 6/2007) ......................................................................................................................................................................................................................................................................................298 WIRE HARNESS LIGHTS (6/2007 →) ......................................................................................................................................................................................................................................................................................................300 TRANSMISSION..............................................................................................................................................................................................................................................................................................................................303 TRANSMISSION MOUNT....................................................................................................................................................................................................................................................................................................................307 TORQUE CONVERTER GM 4.3L, GASOLINE AND LPG............................................................................................................................................................................................................................................................................................308 TRANSMISSION COOLING GM 4.3L, GASOLINE AND LPG, WITH INTERNAL OIL COOLER - BASIC POWERSHIFT TRANSMISSION (→ S/N G004V04081F) .......................................................................................................................................................................................................310 TRANSMISSION COOLING GM 4.3L, LPG, WITH INTERNAL OIL COOLER - BASIC POWERSHIFT TRANSMISSION (S/N G004V04082F →) ....................................................................................................................................................................................................................312 TRANSMISSION COOLING WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (→ S/N G004V04081F) .......................................................................................................................................................................................................................................314 TRANSMISSION COOLING WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION (S/N G004V04082F →) .......................................................................................................................................................................................................................................316 TRANSMISSION SINGLE SPEED, THREE PIECE HOUSING - SHEET 1 OF 2 (→ S/N G004V02079E EXC. 1698) ........................................................................................................................................................................................................................................318 TRANSMISSION SINGLE SPEED, THREE PIECE HOUSING - SHEET 2 OF 2 (→ S/N G004V02079E EXC. 1698) ........................................................................................................................................................................................................................................322 TRANSMISSION SINGLE SPEED, THREE PIECE HOUSING - SHEET 1 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698) .................................................................................................................................................................................................................................324 TRANSMISSION SINGLE SPEED, THREE PIECE HOUSING - SHEET 2 OF 2 (S/N G004V02080E ↔ 9/2007 INC. 1698) .................................................................................................................................................................................................................................328 TRANSMISSION SINGLE SPEED, TWO PIECE HOUSING - SHEET 1 0F 2 (9/2007 →) .............................................................................................................................................................................................................................................................330 TRANSMISSION SINGLE SPEED, TWO PIECE HOUSING - SHEET 2 0F 2 (9/2007 →) .............................................................................................................................................................................................................................................................334 FORWARD CLUTCH SINGLE SPEED TRANSMISSION (→ S/N G004V02079E) ........................................................................................................................................................................................................................................................................336 FORWARD CLUTCH SINGLE SPEED TRANSMISSION (S/N G004V02080E →) ........................................................................................................................................................................................................................................................................338 FORWARD CLUTCH, HIGH DUAL SPEED TRANSMISSION (→ S/N G004V02223E) ....................................................................................................................................................................................................................................................................340 FORWARD CLUTCH, HIGH DUAL SPEED TRANSMISSION (S/N G004V02224E →) ....................................................................................................................................................................................................................................................................342 FORWARD CLUTCH, LOW DUAL SPEED TRANSMISSION (→ S/N G004V02223E) .....................................................................................................................................................................................................................................................................344 FORWARD CLUTCH, LOW DUAL SPEED TRANSMISSION (S/N G004V02224E →) .....................................................................................................................................................................................................................................................................346 REVERSE CLUTCH SINGLE SPEED TRANSMISSION (→ S/N G004V02079E) ........................................................................................................................................................................................................................................................................348 REVERSE CLUTCH SINGLE SPEED TRANSMISSION (S/N G004V02080E →) ........................................................................................................................................................................................................................................................................350 REVERSE CLUTCH DUAL SPEED TRANSMISSION (→ S/N G004V02223E) ..........................................................................................................................................................................................................................................................................352 REVERSE CLUTCH DUAL SPEED TRANSMISSION (S/N G004V02224E →) ..........................................................................................................................................................................................................................................................................354 TRANSMISSION DUAL SPEED, THREE PIECE HOUSING - SHEET 1 OF 2 (→ S/N G004V02228E (WET BRAKE)) (→ S/N G004V02223E DRY BRAKE) .........................................................................................................................................................................................................356 TRANSMISSION DUAL SPEED, THREE PIECE HOUSING - SHEET 2 OF 2 (→ S/N G004V00228E (WET BRAKE)) (→ S/N G004V02223E DRY BRAKE) .........................................................................................................................................................................................................360 TRANSMISSION DUAL SPEED, THREE PIECE HOUSING, SHEET 1 OF 2 (S/N G004V02224E ↔ S/N G004V02842E DRY BRAKE) (S/N G004V02229E ↔ S/N G004V02846E WET BRAKE) .............................................................................................................................................................................362 TRANSMISSION DUAL SPEED, THREE PIECE HOUSING, SHEET 2 OF 2 (S/N G004V02224E ↔ S/N G004V02842E DRY BRAKE) (S/N G004V02229E ↔ S/N G004V02846E WET BRAKE) .............................................................................................................................................................................365 TRANSMISSION DUAL SPEED, TWO PIECE HOUSING - SHEET 1 OF 2 (S/N G004V02843E → (DRY BRAKE)) (S/N G004V02847E → (WET BRAKE)) .........................................................................................................................................................................................................368 TRANSMISSION DUAL SPEED, TWO PIECE HOUSING - SHEET 2 OF 2 (S/N G004V02843E → (DRY BRAKE)) (S/N G004V02847E → (WET BRAKE)) .........................................................................................................................................................................................................372 TRANSMISSION CONTROL VALVE ASSEMBLY...................................................................................................................................................................................................................................................................................................376 TRANSMISSION CONTROL VALVE ASSEMBLY...................................................................................................................................................................................................................................................................................................378 Drive Axle................................................................................................................................................................................................................................................................................................................................379 DRIVE AXLE DRY BRAKE..................................................................................................................................................................................................................................................................................................................382 DRIVE AXLE AND ATTACHING PARTS WET BRAKE (→ S/N G004V01514D) ........................................................................................................................................................................................................................................................................386 DRIVE AXLE AND ATTACHING PARTS WET BRAKE (S/N G004V01515D →) ........................................................................................................................................................................................................................................................................388 DRIVE AXLE HOUSING AND HUB WET BRAKE..................................................................................................................................................................................................................................................................................................390 DIFFERENTIAL DRY BRAKE................................................................................................................................................................................................................................................................................................................394 DIFFERENTIAL WET BRAKE................................................................................................................................................................................................................................................................................................................396 CARRIER ASSEMBLY DRY BRAKE............................................................................................................................................................................................................................................................................................................400 WET BRAKES............................................................................................................................................................................................................................................................................................................................402 DRIVE TIRE AND WHEEL..................................................................................................................................................................................................................................................................................................................404 STEERING SYSTEM...........................................................................................................................................................................................................................................................................................................................405 STEERING COLUMN AND ATTACHING PARTS...................................................................................................................................................................................................................................................................................................408 STEERING COLUMN ASSEMBLY..............................................................................................................................................................................................................................................................................................................410 STEERING CONTROL UNIT.................................................................................................................................................................................................................................................................................................................412 STEER AXLE............................................................................................................................................................................................................................................................................................................................414 STEERING LINES........................................................................................................................................................................................................................................................................................................................418 STEER CYLINDER........................................................................................................................................................................................................................................................................................................................420 STEER TIRES AND WHEELS................................................................................................................................................................................................................................................................................................................422 BRAKE SYSTEM..............................................................................................................................................................................................................................................................................................................................423 BRAKE ASSEMBLY S80FT, S80-100FTBCS - DRY BRAKE .......................................................................................................................................................................................................................................................................................426 BRAKE ASSEMBLY S100-120FT, S120FTS, S120FTPRS - DRY BRAKE ............................................................................................................................................................................................................................................................................428 BRAKE LINKAGE SINGLE PEDAL - DRY BRAKE ...............................................................................................................................................................................................................................................................................................430 BRAKE LINKAGE DUAL PEDAL - DRY BRAKE .................................................................................................................................................................................................................................................................................................434 BRAKE LINKAGE SINGLE PEDAL - WET BRAKE ...............................................................................................................................................................................................................................................................................................438 BRAKE LINKAGE DUAL PEDAL - WET BRAKE .................................................................................................................................................................................................................................................................................................442 BRAKE MASTER CYLINDER ASSEMBLY........................................................................................................................................................................................................................................................................................................445 PARKING BRAKE ASSEMBLY................................................................................................................................................................................................................................................................................................................448 BRAKE COOLING SYSTEM SINGLE AND DUAL PEDAL - WET BRAKE (→ S/N G004V01514D) .........................................................................................................................................................................................................................................................450 BRAKE COOLING SYSTEM SINGLE AND DUAL PEDAL - WET BRAKE (S/N G004V01515D →) .........................................................................................................................................................................................................................................................452 HYDRAULIC SYSTEM..........................................................................................................................................................................................................................................................................................................................455 HYDRAULIC SUPPLY AND RETURN...........................................................................................................................................................................................................................................................................................................458 HYDRAULIC FILTER......................................................................................................................................................................................................................................................................................................................462 HYDRAULIC OIL COOLER..................................................................................................................................................................................................................................................................................................................464 GEAR PUMP.............................................................................................................................................................................................................................................................................................................................466 HAND LEVERS THREE FUNCTION - WITH DETENTED LEVERS ....................................................................................................................................................................................................................................................................................468 HAND LEVERS THREE FUNCTION - WITHOUT DETENTED LEVERS .................................................................................................................................................................................................................................................................................470 HAND LEVERS FOUR FUNCTION - WITH DETENTED LEVERS .....................................................................................................................................................................................................................................................................................472 HAND LEVERS FOUR FUNCTION - WITHOUT DETENTED LEVERS ..................................................................................................................................................................................................................................................................................474 MANUAL CONTROL VALVE ASSEMBLY THREE AND FOUR FUNCTION.................................................................................................................................................................................................................................................................................476 MANUAL CONTROL VALVE LOCKOUT GROUP....................................................................................................................................................................................................................................................................................................478 MANUAL CONTROL VALVE LIFT AND TILT - THREE AND FOUR FUNCTION (→ S/N G004V02934E (Three Function)) (→ S/N G004V02942E (Four Function)) .............................................................................................................................................................................................480 MANUAL CONTROL VALVE LIFT AND TILT - THREE AND FOUR FUNCTION (S/N G004V02935E → (Three Function)) (S/N G004V02943E → (Four Function)) .............................................................................................................................................................................................482 MANUAL CONTROL VALVE LIFT AND TILT - THREE AND FOUR FUNCTION (S/N G004V04302G →) ...................................................................................................................................................................................................................................................484 MANUAL CONTROL VALVE AUXILIARY ONE AND TWO SECTION - THREE AND FOUR FUNCTION (→ S/N G004V02934E (Three Function)) (→ S/N G004V02942E (Four Function)) .............................................................................................................................................................................486 MANUAL CONTROL VALVE AUXILIARY ONE AND TWO SECTION - THREE AND FOUR FUNCTION (S/N G004V02935E → (Three Function)) (S/N G004V02943E → (Four Function)(Four Function)) .............................................................................................................................................................488 MANUAL CONTROL VALVE OUTLET SECTION - THREE, FOUR, AND FIVE FUNCTION .................................................................................................................................................................................................................................................................490 ELECTRONIC CONTROL VALVE ASSEMBLY THREE FUNCTION (→ S/N G004V04328G) ................................................................................................................................................................................................................................................................492 ELECTRONIC CONTROL VALVE ASSEMBLY THREE FUNCTION (S/N G004V04329G →) ................................................................................................................................................................................................................................................................494 ELECTRONIC CONTROL VALVE ASSEMBLY FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ........................................................................................................................................................................................................................................................496 ELECTRONIC CONTROL VALVE ASSEMBLY FOUR AND FIVE FUNCTION (S/N G004V04329G →) ........................................................................................................................................................................................................................................................498 ELECTRONIC CONTROL VALVE LIFT AND LOWER - THREE, FOUR, AND FIVE FUNCTION .............................................................................................................................................................................................................................................................500 ELECTRONIC HYDRAULIC POPPET VALVE THREE, FOUR AND FIVE FUNCTION.......................................................................................................................................................................................................................................................................502 ELECTRONIC CONTROL VALVE TILT SECTION - THREE, FOUR, AND FIVE FUNCTION ...............................................................................................................................................................................................................................................................504 ELECTRONIC CONTROL VALVE AUXILIARY ONE SECTION - THREE, FOUR AND FIVE FUNCTION (→ S/N G004V04328G) .................................................................................................................................................................................................................................506 ELECTRONIC CONTROL VALVE AUXILIARY ONE SECTION - THREE, FOUR AND FIVE FUNCTION (S/N G004V04329G →) .................................................................................................................................................................................................................................508 ELECTRONIC CONTROL VALVE AUXILIARY TWO SECTION - FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ........................................................................................................................................................................................................................................510 ELECTRONIC CONTROL VALVE AUXILIARY TWO SECTION - FOUR AND FIVE FUNCTION (S/N G004V04329G →) ........................................................................................................................................................................................................................................512 ELECTRONIC CONTROL VALVE OUTLET SECTION - THREE, FOUR AND FIVE FUNCTION (→ S/N G004V04328G) ........................................................................................................................................................................................................................................514 ELECTRONIC CONTROL VALVE OUTLET SECTION - THREE, FOUR AND FIVE FUNCTION (S/N G004V04329G →) ........................................................................................................................................................................................................................................516 TILT CYLINDER INSTALLATION............................................................................................................................................................................................................................................................................................................518 TILT CYLINDER.........................................................................................................................................................................................................................................................................................................................520 TILT HOSES............................................................................................................................................................................................................................................................................................................................522 AUXILIARY HOSES.......................................................................................................................................................................................................................................................................................................................524 VENT LINE GROUP.......................................................................................................................................................................................................................................................................................................................526 Mast-Two Stage Limited Free-Lift..........................................................................................................................................................................................................................................................................................................527 INNER MAST TWO STAGE LIMITED FREE-LIFT................................................................................................................................................................................................................................................................................................530 OUTER MAST TWO STAGE LIMITED FREE-LIFT................................................................................................................................................................................................................................................................................................532 MAIN LIFT TWO STAGE LIMITED FREE-LIFT.................................................................................................................................................................................................................................................................................................534 MAIN LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT - S80FT ...............................................................................................................................................................................................................................................................................538 MAIN LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT - S100-120FT ..........................................................................................................................................................................................................................................................................540 HEADER HOSE TWO STAGE LIMITED FREE-LIFT...............................................................................................................................................................................................................................................................................................542 CARRIAGE TWO STAGE LIMITED FREE-LIFT..................................................................................................................................................................................................................................................................................................546 Mast-Two Stage Full Free-Lift.............................................................................................................................................................................................................................................................................................................549 INNER MAST AND FREE-LIFT TWO STAGE FULL FREE-LIFT - S80-120FT ........................................................................................................................................................................................................................................................................552 OUTER MAST AND MAIN LIFT TWO STAGE FULL FREE-LIFT - S80-120FT ........................................................................................................................................................................................................................................................................556 MAIN LIFT CYLINDER TWO STAGE FULL FREE-LIFT - S80-120FT ..............................................................................................................................................................................................................................................................................560 FREE-LIFT CYLINDER TWO STAGE FULL FREE-LIFT - S80-120FT ..............................................................................................................................................................................................................................................................................564 HEADER HOSE TWO STAGE FULL FREE-LIFT - S80-120FT .....................................................................................................................................................................................................................................................................................568 CARRIAGE TWO STAGE FULL FREE-LIFT - S80-120FT ........................................................................................................................................................................................................................................................................................572 Mast-Three Stage Full Free-Lift...........................................................................................................................................................................................................................................................................................................575 INNER MAST THREE STAGE FULL FREE-LIFT.................................................................................................................................................................................................................................................................................................578 OUTER MAST THREE STAGE FULL FREE-LIFT.................................................................................................................................................................................................................................................................................................580 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT..........................................................................................................................................................................................................................................................................................584 MAIN LIFT THREE STAGE FULL FREE-LIFT..................................................................................................................................................................................................................................................................................................588 MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT.........................................................................................................................................................................................................................................................................................592 FREE-LIFT THREE STAGE FULL FREE-LIFT..................................................................................................................................................................................................................................................................................................596 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT.........................................................................................................................................................................................................................................................................................600 HEADER HOSE THREE STAGE FULL FREE-LIFT................................................................................................................................................................................................................................................................................................604 CARRIAGE THREE STAGE FULL FREE-LIFT...................................................................................................................................................................................................................................................................................................608 OPTIONS...................................................................................................................................................................................................................................................................................................................................611 BOLT-ON FENDERS.......................................................................................................................................................................................................................................................................................................................614 STROBE LIGHT..........................................................................................................................................................................................................................................................................................................................616 STROBE LIGHT LED (S/N G004V02784E → INC. 02746, 02754-02758) ........................................................................................................................................................................................................................................................................618 MIRROR................................................................................................................................................................................................................................................................................................................................619 MIRROR REAR MOUNTED...................................................................................................................................................................................................................................................................................................................620 FIRE EXTINGUISHER.....................................................................................................................................................................................................................................................................................................................621 BACK-UP ALARM.........................................................................................................................................................................................................................................................................................................................622 BACK-UP ALARM.........................................................................................................................................................................................................................................................................................................................624 PRESSURE REGULATOR....................................................................................................................................................................................................................................................................................................................626 GM LPG REGULATOR DRAIN KIT............................................................................................................................................................................................................................................................................................................628 ACCUMULATOR...........................................................................................................................................................................................................................................................................................................................630 INTEGRAL SIDE-SHIFT TWO STAGE LIMITED FREE-LIFT - S80-120FT ..........................................................................................................................................................................................................................................................................632 INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT - 1067 MM (42 IN.) CLASS III ................................................................................................................................................................................................................................................634 INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS III ................................................................................................................................................................................................................................................636 INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT - 1219 MM (48 IN.) CLASS IV .................................................................................................................................................................................................................................................638 INTEGRAL SIDE-SHIFT TWO STAGE FULL FREE-LIFT - S80FT .................................................................................................................................................................................................................................................................................640 INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT - 1067 MM (42 IN.) CLASS III ...................................................................................................................................................................................................................................................642 INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III ...................................................................................................................................................................................................................................................644 INTEGRAL SIDE-SHIFT THREE STAGE FULL FREE-LIFT - S80FT ...............................................................................................................................................................................................................................................................................646 INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT - 1067 MM (42 IN.) CLASS III .................................................................................................................................................................................................................................................648 INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS III .................................................................................................................................................................................................................................................650 INTEGRAL SIDE-SHIFT TWO AND THREE STAGE FULL FREE-LIFT - S100-120FT ..................................................................................................................................................................................................................................................................652 INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV ....................................................................................................................................................................................................................................................654 INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT - 1219 MM (48 IN.) CLASS IV ..................................................................................................................................................................................................................................................656 AUXILIARY TUBE EXTENSIONS TWO STAGE LIMITED FREE-LIFT.................................................................................................................................................................................................................................................................................658 AUXILIARY TUBE EXTENSIONS TWO STAGE FULL FREE-LIFT - THREE FUNCTION ..................................................................................................................................................................................................................................................................660 AUXILIARY TUBE EXTENSIONS THREE STAGE FULL FREE-LIFT..................................................................................................................................................................................................................................................................................662 FIELD CONVERSION KITS.....................................................................................................................................................................................................................................................................................................................665 BRAKE AND INCHING PEDAL CONVERSION....................................................................................................................................................................................................................................................................................................668 ADD-ON OPTION KITS....................................................................................................................................................................................................................................................................................................................668 LIGHT KITS............................................................................................................................................................................................................................................................................................................................668 AUDIBLE ALARM KITS....................................................................................................................................................................................................................................................................................................................668 E-HYDRAULIC CONTROL CONVERSION KITS...................................................................................................................................................................................................................................................................................................669 MANUAL HYDRAULIC CONTROL CONVERSION KITS..............................................................................................................................................................................................................................................................................................669 HEADER HOSE CONVERSION KITS TWO STAGE LIMITED FREE-LIFT...............................................................................................................................................................................................................................................................................671 HEADER HOSE CONVERSION KITS TWO STAGE FULL FREE-LIFT..................................................................................................................................................................................................................................................................................672 HEADER HOSE CONVERSION KITS THREE STAGE FULL FREE-LIFT................................................................................................................................................................................................................................................................................673 AUXILIARY TUBE EXTENSION KIT..........................................................................................................................................................................................................................................................................................................674 MISCELLANEOUS.........................................................................................................................................................................................................................................................................................................................675 REPLACEMENT KITS E. HYDRAULIC CONTROL VALVES - WITH ANTI-STALL .......................................................................................................................................................................................................................................................................675 NUMERICAL INDEX...........................................................................................................................................................................................................................................................................................................................677
HYSTER FORTIS® S80FT-120FT, S80-100FTBCS, S120FTS, S120FTPRS (G004) PARTS MANUAL – PDF DOWNLOAD:
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