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Hyster J80XN J90XN J100XN (A970) Parts Manual – PDF DOWNLOAD
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Hyster J80XN J90XN J100XN (A970) Parts Manual – PDF DOWNLOAD
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Description
Hyster J80XN J90XN J100XN (A970) Parts Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster J80XN J90XN J100XN (A970) Parts Manual – PDF DOWNLOAD
HOW TO USE THE ILLUSTRATED PARTS MANUAL :
- This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.
- The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.
HOW TO FIND THE DESIRED PART NUMBER
WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:
1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.
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 12-1) 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 12-1) 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 Supersession Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.
- Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (FFigure 10)
7. 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 J80XN J90XN J100XN (A970) Parts Manual – PDF DOWNLOAD
Frame...................................................................................................... 17 HOOD................................................................................................... 20 OVERHEAD GUARD......................................................................................... 24 FENDERS................................................................................................ 26 COUNTERWEIGHT.......................................................................................... 28 OPERATOR COMPARTMENT................................................................................... 30 OPERATOR COMPARTMENT................................................................................... 32 SEATS NON SUSPENSION - WITH HIP RESTRAINTS ............................................................ 34 SEATS FULL SUSPENSION - SHEET 1 0F 2 .................................................................. 36 SEATS FULL SUSPENSION - SHEET 2 OF 2 .................................................................. 40 ARMREST SLIDER ASSEMBLY................................................................................ 42 CAB FRONT PANEL AND WIPER.............................................................................. 44 CAB FRONT PANEL ASSEMBLY............................................................................... 46 CAB REAR PANEL......................................................................................... 48 CAB REAR PANEL ASSEMBLY................................................................................ 50 CAB HEADLINER.......................................................................................... 52 CAB DOOR INSTALLATION.................................................................................. 54 CAB LEFT HAND DOOR ASSEMBLY - WITH HORIZONTAL BATTERY REMOVAL ......................................... 56 CAB RIGHT HAND DOOR ASSEMBLY - WITH HORIZONTAL BATTERY REMOVAL ........................................ 58 CAB WINDOW - LH DOOR .................................................................................. 60 CAB WINDOW - RH DOOR .................................................................................. 62 CAB HEATER............................................................................................. 64 CAB TOP PANEL.......................................................................................... 66 DASH AND STEERING COLUMN COVERS FIXED COLUMN........................................................... 68 DASH AND STEERING COLUMN COVERS TELESCOPIC COLUMN...................................................... 70 COUNTERWEIGHT AND BATTERY COVERS....................................................................... 72 FLOORPLATES, STEPS AND COVERS.......................................................................... 74 BATTERY REMOVAL AND SPACERS HORIZONTAL BATTERY REMOVAL................................................. 76 BATTERY REMOVAL AND SPACERS VERTICAL BATTERY REMOVAL................................................... 80 NAMEPLATES AND LABELS SHEET 1 OF 2..................................................................... 82 NAMEPLATES AND LABELS SHEET 2 OF 2..................................................................... 84 NAMEPLATES AND LABELS HYDRAULIC CONTROL FUNCTIONS...................................................... 86 SOUND LINERS........................................................................................... 88 LOAD BACKREST.......................................................................................... 90 FORKS STANDARD TAPER CLASS III AND CLASS IV............................................................ 92 FORKS POLISHED FORK WITH FULL BOTTOM TAPER - CLASS III AND CLASS IV ................................... 94 FORKS OPTIONAL LATCH................................................................................... 95 FORKS WITH LATCH CLASS III - OPTIONAL ................................................................. 96 FORKS CLASS IV - OPTIONAL ............................................................................. 97 ELECTRICAL SYSTEM.......................................................................................... 99 ELECTRICAL ARRANGEMENT.................................................................................104 LIGHTS TAIL, BACK-UP, AND STROBE.......................................................................108 BATTERY CONNECTOR......................................................................................110 CONTACTOR AND FUSE MOUNTING UL-E.......................................................................112 CONTACTOR AND FUSE MOUNTING UL-EE......................................................................114 CONTACTOR ASSEMBLY UL-EE...............................................................................116 CONTACTOR ASSEMBLY UL-E 36/48V.........................................................................118 CONTROL PANEL PUMP MOTOR...............................................................................119 CONTROL PANEL TRACTION MOTOR...........................................................................120 POWER CABLES...........................................................................................122 DRIP PLATE, STATIC STRAP AND ATTACHING PARTS...........................................................125 TILT SENSOR GROUP......................................................................................126 DISPLAY................................................................................................127 AUXILIARY PLUG AND WIRE HARNESS........................................................................128 FUSE ASSEMBLY FRONT WIPER..............................................................................129 MINI-LEVER CONTROLS 3 FUNCTION.........................................................................130 MINI-LEVER CONTROLS 4 FUNCTION.........................................................................132 WIRE HARNESS AUXILIARY PLUG............................................................................134 WIRE HARNESS EMERGENCY DISCONNECT......................................................................135 WIRE HARNESS FRONT WIPER...............................................................................136 WIRE HARNESS JUMPER - WITH DIODES .....................................................................138 WIRE HARNESS MAIN WITH MANUAL HYDRAULICS - SHEET 1 OF 2 (→ S/N A970B01656L) .........................140 WIRE HARNESS MAIN WITH MANUAL HYDRAULICS - SHEET 2 OF 2 (→ S/N A970B01656L) .........................146 WIRE HARNESS MAIN WITH MANUAL HYDRAULICS - SHEET 1 OF 2 (S/N A970B01657L →) .........................150 WIRE HARNESS MAIN WITH MANUAL HYDRAULICS - SHEET 2 OF 2 (S/N A970B01657L →) .........................156 WIRE HARNESS MAIN WITH ELECTRO-HYDRAULICS - SHEET 1 OF 2 (→ S/N A970B01656L) ........................160 WIRE HARNESS MAIN WITH ELECTRO-HYDRAULICS - SHEET 2 OF 2 (→ S/N A970B01656L) ........................166 WIRE HARNESS MAIN WITH ELECTRO-HYDRAULICS - SHEET 1 OF 2 (S/N A970B01657L →) ........................170 WIRE HARNESS MAIN WITH ELECTRO-HYDRAULICS - SHEET 2 OF 2 (S/N A970B01657L →) ........................176 WIRE HARNESS MANUAL INTERLOCK..........................................................................179 WIRE HARNESS LEFT HAND FRONT SWITCH....................................................................180 WIRE HARNESS LH LIGHTS WITH OVERHEAD GUARD - WITHOUT TURN SIGNALS (→ 10/2013) .......................182 WIRE HARNESS LH LIGHTS WITH OVERHEAD GUARD - WITHOUT TURN SIGNALS (10/2013 →) .......................184 WIRE HARNESS REAR WIPER................................................................................186 WIRE HARNESS RH LIGHT WITH STANDARD DISPLAY - WITHOUT TURN SIGNALS (→ 10/2013) ......................187 WIRE HARNESS RH LIGHT WITH STANDARD DISPLAY - WITHOUT TURN SIGNALS (10/2013 →) ......................188 WIRE HARNESS RH LIGHT WITH FREEZER DISPLAY - WITH TURN SIGNALS (→ 10/2013) ..........................190 WIRE HARNESS RH LIGHT WITH FREEZER DISPLAY - WITH TURN SIGNALS (10/2013 →) ..........................192 WIRE HARNESS RH LIGHT WITH STANDARD DISPLAY - DRIVE-IN RACK WITHOUT TURN SIGNAL (→ 10/2013) .........194 WIRE HARNESS RH LIGHT WITH STANDARD DISPLAY - DRIVE-IN RACK WITHOUT TURN SIGNAL (10/2013 →) .........196 WIRE HARNESS RH LIGHT WITH FREEZER DISPLAY - DRIVE-IN RACK WITH TURN SIGNAL (→ 10/2013) .............198 WIRE HARNESS RH LIGHT WITH FREEZER DISPLAY - DRIVE-IN RACK WITH TURN SIGNAL (10/2013 →) .............200 WIRE HARNESS SEAT - MANUAL HYDRAULIC ..................................................................201 WIRE HARNESS SEAT - E-HYDRAULIC .......................................................................202 WIRE HARNESS STEERING COLUMN...........................................................................204 DRIVE UNIT.................................................................................................207 TRANSAXLE AND ATTACHING PARTS..........................................................................210 TRANSAXLE ASSEMBLY SHEET 1 OF 3........................................................................212 TRANSAXLE ASSEMBLY SHEET 2 OF 3........................................................................214 TRANSAXLE ASSEMBLY SHEET 3 OF 3........................................................................216 DRIVE TIRES AND WHEELS J80-90XN........................................................................218 DRIVE TIRES AND WHEELS J100XN..........................................................................219 STEERING SYSTEM............................................................................................221 STEER AXLE AND ATTACHING PARTS.........................................................................224 STEERING ACCUMULATOR...................................................................................227 STEER TIRE AND WHEEL...................................................................................228 STEER PUMP ASSEMBLY....................................................................................230 STEERING CYLINDER......................................................................................232 STEERING WHEEL AND COLUMN FIXED........................................................................234 STEERING WHEEL AND COLUMN TELESCOPIC...................................................................235 STEERING COLUMN ASSEMBLY FIXED (→ 10/2013) ...........................................................236 STEERING COLUMN ASSEMBLY FIXED (10/2013 →) ...........................................................238 STEERING COLUMN ASSEMBLY TELESCOPIC (→ 10/2013) ......................................................240 STEERING COLUMN ASSEMBLY TELESCOPIC (10/2013 →) ......................................................241 BRAKE/ACCELERATOR SYSTEM...................................................................................243 ACCELERATOR PEDAL ASSEMBLY (STANDARD)..................................................................246 ACCELERATOR PEDAL ASSEMBLY (MONOTROL)..................................................................247 BRAKE SYSTEM...........................................................................................248 BRAKE SYSTEM...........................................................................................250 BRAKE ASSEMBLY.........................................................................................252 MASTER CYLINDER........................................................................................254 PARKING BRAKE VALVE....................................................................................256 HYDRAULIC SYSTEM...........................................................................................257 HYDRAULIC SUPPLY AND RETURN............................................................................260 HYDRAULIC SUPPLY AND RETURN WITH OIL COOLER AND VENTED SIDE PANELS.....................................262 HYDRAULIC HOSES HOIST, TILT AND MAST...................................................................264 HYDRAULIC HOSES STEERING...............................................................................266 HYDRAULIC TANK AND ATTACHING PARTS.....................................................................268 HYDRAULIC PUMP AND MOTOR STANDARD PUMP.................................................................270 HYDRAULIC PUMP 33 cc...................................................................................272 OIL COOLER.............................................................................................274 MANUAL CONTROL LEVERS..................................................................................276 HYDRAULIC CONTROL VALVE AND FITTINGS MANUAL HYDRAULIC - THREE AND FOUR FUNCTION .......................279 HYDRAULIC CONTROL VALVE ASSEMBLY MANUAL HYDRAULIC - THREE AND FOUR FUNCTION ...........................280 VALVE ASSEMBLY LIFT, TILT, AND AUXILIARY - MANUAL HYDRAULIC ...........................................282 VALVE ASSEMBLY INLET SECTION - MANUAL AND ELECTRONIC ..................................................284 HYDRAULIC CONTROL VALVE AND FITTINGS ELECTRO-HYDRAULIC - THREE AND FOUR FUNCTION ......................286 HYDRAULIC CONTROL VALVE ASSEMBLY ELECTRONIC - THREE AND FOUR FUNCTION .................................288 VALVE ASSEMBLY LIFT, TILT, AND AUXILIARY - ELECTRIC HYDRAULIC .........................................290 TILT CYLINDER AND MAST INSTALLATION....................................................................292 TILT CYLINDER ASSEMBLY.................................................................................294 HYDRAULIC MOTOR ASSEMBLY...............................................................................296 Mast-Two Stage Limited Free-Lift...........................................................................299 MAST ASSEMBLY OUTER MAST - TWO STAGE LIMITED FREE-LIFT ................................................302 MAST ASSEMBLY INNER MAST - TWO STAGE LIMITED FREE-LIFT ................................................304 MAST ASSEMBLY MAIN LIFT - TWO STAGE LIMITED FREE-LIFT (→ PENDING PER ECN 15482602) ..................306 MAST ASSEMBLY MAIN LIFT - TWO STAGE LIMITED FREE-LIFT (PENDING PER ECN 15482602 →) ..................310 MAST ASSEMBLY MAIN CYLINDER (J80-90XN) - TWO STAGE LIMITED FREE-LIFT ..................................314 MAST ASSEMBLY MAIN CYLINDER (J100XN) - TWO STAGE LIMITED FREE-LIFT ....................................316 HEADER HOSE TWO STAGE LIMITED FREE-LIFT................................................................318 CARRIAGE TWO STAGE LIMITED FREE-LIFT...................................................................320 ATTACHMENT CARRIAGE TWO STAGE LIMITED FREE-LIFT - J100XN ..............................................322 Mast-Three Stage Full Free-Lift............................................................................325 MAST ASSEMBLY THREE STAGE FULL FREE LIFT - OUTER MAST .................................................328 MAST ASSEMBLY THREE STAGE FULL FREE LIFT - INTERMEDIATE MAST ..........................................330 MAST ASSEMBLY THREE STAGE FULL FREE LIFT - INNER MAST AND FREE LIFT (→ PENDING PER ECN 15482602) ....332 MAST ASSEMBLY THREE STAGE FULL FREE LIFT - INNER MAST AND FREE LIFT (PENDING PER ECN 15482602 →) ....336 MAST ASSEMBLY THREE STAGE FULL FREE LIFT - MAIN LIFT (→ PENDING PER ECN 15482602) ...................340 MAST ASSEMBLY THREE STAGE FULL FREE LIFT - MAIN LIFT (PENDING PER ECN 15482602 →) ...................344 MAST ASSEMBLY THREE STAGE FULL FREE LIFT - MAIN LIFT CYLINDER ASSEMBLY ................................348 MAST ASSEMBLY THREE STAGE FULL FREE LIFT - FREE LIFT CYLINDER ASSEMBLY ................................352 HEADER HOSE THREE STAGE FULL FREE-LIFT.................................................................356 CARRIAGE THREE STAGE FULL FREE LIFT....................................................................360 ATTACHMENT CARRIAGE THREE STAGE FULL FREE-LIFT - J100XN ...............................................362 Mast-Two Stage Full Free-Lift..............................................................................365 MAST TWO STAGE FULL FREE LIFT - OUTER MAST AND MAIN LIFT ..............................................368 MAST TWO STAGE FULL FREE LIFT - INNER MAST AND FREE LIFT ..............................................372 MAST TWO STAGE FULL FREE LIFT - MAIN LIFT CYLINDER ....................................................376 MAST TWO STAGE FULL FREE LIFT - FREE LIFT CYLINDER ....................................................380 HEADER HOSE TWO STAGE FULL FREE-LIFT...................................................................384 CARRIAGE TWO STAGE FULL FREE-LIFT......................................................................388 ATTACHMENT CARRIAGE TWO STAGE FULL FREE-LIFT - J100XN .................................................390 OPTIONS....................................................................................................393 MIRROR (STANDARD)......................................................................................396 MIRROR (PANORAMIC).....................................................................................398 REAR DRIVE HANDLE......................................................................................400 ACCUMULATOR............................................................................................402 IMPACT SENSOR..........................................................................................404 INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE LIMITED FREE-LIFT - J80-90XN ...................................406 INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT - J80-90XN ...................................408 INTEGRAL SIDE-SHIFT ASSEMBLY TWO STAGE LIMITED FREE LIFT - J100XN .....................................410 INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE LIFT - J100XN .....................................412 INTEGRAL SIDE-SHIFT ASSEMBLY TWO AND THREE STAGE FULL FREE-LIFT - J80-90XN ............................414 INTEGRAL SIDE-SHIFT CARRIAGE TWO AND THREE STAGE FULL FREE-LIFT - J80-90XN ............................416 INTEGRAL SIDE-SHIFT ASSEMBLY TWO AND THREE STAGE FULL FREE-LIFT - J100XN ..............................418 INTEGRAL SIDE-SHIFT CARRIAGE TWO AND THREE STAGE FULL FREE-LIFT - J100XN ..............................420 TRACTION SPEED LIMITER STANDARD AND INTEGRAL SIDE-SHIFT CARRIAGES......................................422 FIELD CONVERSION KITS......................................................................................425 HYDRAULIC CONVERSION KITS..............................................................................428 MISCELLANEOUS CONVERSION KITS..........................................................................428 ADD-ON OPTION KITS.....................................................................................428 ADD ON OPTIONS LIGHT KITS..............................................................................429 ADD ON TELEMETRY KITS..................................................................................429 CAB KITS WHEN SELECTING ANY CAB KIT THE APPROPRIATE INSTALLATION KIT SHOULD ALSO BE SELECTED...........429 NUMERICAL INDEX............................................................................................431
HYSTER J80XN J90XN J100XN (A970) PARTS MANUAL – PDF DOWNLOAD:
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