Hyster H80-H120FT Forklift Parts Manual 2012 – PDF Download

Description

Hyster H80-H120FT Parts Manual – Instant PDF Reference

This is the complete Hyster H80-H120FT Forklift Parts Manual published under document number 4047190 and dated 01/2012 for Unit Code R005. It covers the H80FT, H90FT, H100FT, H110FT and H120FT counterbalanced lift trucks in gasoline, LPG and diesel configurations. Every major assembly is broken down into its components with item call-outs, Hyster part numbers, descriptions, required quantities and serial-number break information so the correct part is identified the first time. Because this is a genuine illustrated parts manual rather than a generic catalogue, the exploded diagrams and detail views map directly to what is on the truck.

File Details

• Manual type: Illustrated Parts Manual
• Brand / manufacturer: Hyster Company
• Model series: H80FT, H90FT, H100FT, H110FT, H120FT
• Unit code: R005
• Document number: 4047190
• Publication date: 01/2012
• Language: English
• File format: PDF
• Page count: approximately 708 pages
• Sectioning: 16 major sections plus a full numerical index

Chapters Covered

The manual is divided into sixteen major tabbed sections, each with its own table of contents, so a technician can go straight to the assembly group instead of hunting page by page:

• 1 – Frame: hood assembly, fender extensions, overhead guard, counterweight, cab assembly with steel doors, windows and wipers, armrest and mini-lever modules, floor plates and covers, labels, forks, load backrest extension
• 2 – Engine Assembly (Diesel): Kubota 3.8L diesel – exhaust system, cooling, fan shroud, compressor, engine mount and torque converter, flywheel and housing, cylinder block, cylinder head and covers, inlet and exhaust valves, camshaft, fuel injection pump, fuel rail and injection pipes, EGR, turbocharger, water pump, sensors, starter
• 3 – Engine Assembly (GM): GM 4.3L gasoline and LPG – cooling, exhaust manifolds, flywheel and housing, fan assembly, cylinder head and block, valve cover and inlet manifold, intake air fuel module, distributor and coil, oil pump, thermostat and water outlet, water bypass
• 4 – Fuel System: air filter and intake, pre-cleaner, fuel sender, fuel cap, gasoline and LPG fuel systems, LPG regulator, converter and lock-off, LPG tank brackets (swing-out and drop-down), monotrol pedal, throttle body and pedal
• 5 – Electrical System: right-hand chassis harness, engine electrical, battery cables and disconnect, cowl electrical, lights, control module, fuse box, power distribution module, instrument cluster, alternator, starter, spark plugs and wires, mini-lever controls, mast tilt sensor, load-weigh, impact sensor and every sub-harness
• 6 – Transmission: cooling lines, torque converter, single and dual speed transmission assemblies, forward and reverse clutch packs, transmission control valve
• 7 – Drive Axle: dry brake and wet brake drive axle assemblies, differential, carrier assembly, drive axle housing and hub, drive wheels and tires (single and dual tread)
• 8 – Steering System: steering hoses, steering column and assembly, steer control unit, steer axle, steer cylinder, steer wheels and tires
• 9 – Brake System: dry brake assembly, master cylinder, brake linkage (single and dual pedal, dry and wet brake), brake cooling system, manual park brake
• 10 – Hydraulic System: hydraulic supply and return, filter, gear pump, hand levers, manual and electronic control valve assemblies, electro-hydraulic poppet valve, outlet section, tilt hoses, tilt cylinders and mast installation, vent line group
• 11 – Mast (Two Stage Limited Free-Lift): outer mast and main lift, inner mast, main lift cylinders for H80-90FT and H100-120FT, header hose, header hose auxiliary tube extensions, carriage
• 12 – Mast (Two Stage Full Free-Lift): outer and inner mast, main lift and free lift cylinders, header hose and auxiliary tube extensions, carriage
• 13 – Mast (Three Stage Full Free-Lift): outer, intermediate and inner mast, main chain, main lift cylinder, free lift cylinder, header hose and auxiliary tube extensions, carriage
• 14 – Options: header hose auxiliary tube extensions with quick disconnects, integral side-shift carriage and chain anchor groups, rear drive handle, strobe light, mirrors, fire extinguisher, back-up alarm, accumulator, lifting eyes
• 15 – Field Conversion Kits: hose groups for every mast type, directional control conversions, carriage lockout rods, red seat belt, mini-lever and manual hydraulic control conversions, add-on option kits
• 16 – Numerical Index: complete part-number-to-page listing

Altogether the Hyster H80-H120FT parts manual gives a technician the correct component for nearly any repair on these trucks – engine internals, transmission clutch packs, drive axle differentials, mast chains and cylinders, hydraulic control valves, electrical harnesses, brake hydraulics and cab hardware. Every exploded view shows the order parts go together, and each line item carries the Hyster part number, description and quantity so an order can be placed without guesswork.

How the Listings Are Organised

Each tabbed section opens with its own table of contents and then presents assembly breakdown pages. The example page reproduced in the front of the manual shows the convention clearly: item call-outs on the illustration match numbered rows in the parts table, keys like A, B, C and D distinguish similar assemblies or left/right variants, and indentations show which components are sub-parts of a larger assembly. Quantities shown are for one assembly, so a two-off sub-part really is two per assembly – useful when ordering clutch plates, rollers, shims or fasteners.

Part Numbers, Keys and Footnotes

Hyster part numbers are listed in full, with superseded numbers displayed in the order they were replaced (oldest to newest, with a strikethrough). Where a part is not serviced separately, or where the listing points to a different figure, that is flagged in the description column. Five dots in the part-number column mean the part is not sold separately or a figure reference is required instead. Two dots in the quantity column mean the part does not apply to that particular assembly. The key columns (A, B, C, D, E) let you match the correct variant for your truck’s transmission, brake type or mast configuration.

Serial Number Breaks and Date Breaks

The Hyster H80-H120FT parts manual uses serial-number breaks so that a change introduced mid-production can be ordered correctly. Breaks are printed as “S/N D001H2628 and prior” or “S/N D001H2629 and up” so the correct supersession is obvious. Pending serial numbers tied to an Engineering Change Notice are also shown, and where a change was recorded without a serial break a date break (month/year) is given instead. This is the difference between ordering a component that fits and one that does not.

Why the Hyster H80-H120FT Parts Manual Matters

These trucks use several variants of the same assembly – dry-brake versus wet-brake drive axles, single-speed versus dual-speed transmissions, two-stage limited free-lift, two-stage full free-lift and three-stage full free-lift masts, gasoline, LPG and Kubota diesel engines. The parts manual is the fastest way to identify exactly which version of a part belongs on a specific chassis. Get the part wrong and you are dealing with a returned order, a truck out of service and a missed deadline. Get it right and it is a one-time job.

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This Hyster H80-H120FT forklift parts manual is delivered as an instant PDF download – no shipping, no waiting on the post. Open it on a laptop, tablet or phone in the workshop, or print the assembly pages you need for the job in front of you. Search by part number in the numerical index, jump to the section tab for the system you are working on, and confirm the correct call-out before you place the order. Whether you are rebuilding a mast, servicing a wet brake axle, replacing engine electricals or speccing a field conversion kit, this parts manual is the reference that keeps the H80FT, H90FT, H100FT, H110FT and H120FT trucks running.