Hyster S120FT (H004) Parts Manual PDF – 2013 Illustrated Parts Catalog for S80FT S100FT S120FT Forklift

Description

Hyster S120FT (H004) Parts Manual – Complete Illustrated Parts Catalog

This is the complete illustrated parts manual for the Hyster S120FT (H004) forklift, issued as a Customer Edition and written around the S/N H004V01886L truck. Across 634 pages, this Hyster S120FT parts manual covers every major assembly on the S80FT, S100FT, and S120FT lift trucks, giving you the exact part numbers, descriptions, quantities, and exploded illustrations you need to order replacements with confidence. The contents page breaks the book into 16 major sections, from frame and engines through to masts, options, field conversion kits, and a full numerical index.

File Details

• Manual Type: Illustrated Parts Manual (Customer Edition)
• Brand: Hyster
• Model: S120FT (H004)
• Publication Number: 4063252
• Publication Date: 01/2013
• Language: English
• Page Count: 634
• File Format: PDF
• Region: North America
• Serial Number: H004V01886L

Chapters Covered

This Hyster S120FT H004 parts manual is organised into 16 major sections, each with its own assembly breakdowns and illustrated parts lists:

• Frame – floor plates and covers, hood assembly, counterweight, overhead guard, semi-suspension and full suspension seats, armrest assemblies, mini-lever modules, load backrest extensions, forks, labels and plate locations
• Engines – GM 4.3L and GM 3.4L gasoline/LPG engine assembly, cylinder block, cylinder head, camshaft and oil pan, exhaust system, exhaust wraps, cooling system, fan and fan mount, flywheel and housing, oil pump, intake air fuel module
• Fuel System – air intake system with pre-cleaner and duct, air cleaner, fuel cap, fuel sending unit, fuel supply system, LPG converter, LPG lock-off, LPG regulator and mixer, throttle body, LPG tank brackets for swing-out and drop-down configurations
• Electrical System – cowl electrical, right-hand chassis, engine electrical system, engine control module and sensors, fuse box, alternator and mounting, sealed alternator, starter, distributor assembly, battery cables, mini-lever controls, load weigh, impact sensor, instrument cluster, remote key switch, and a full range of wire harnesses
• Transmission – single speed and dual speed transmission assemblies, torque converter, forward clutch (single speed and dual speed high/low), reverse clutch, transmission control valve assembly, transmission cooling (internal and external oil cooler), transmission mount
• Drive Axle – wet brake NMHG pages 1 to 3, wet brake Dana, differential assembly, drive axle and attaching parts, drive axle housing and hub, wet brakes Dana, drive tire and wheel
• Steering System – steering hoses, steer axle, steer cylinder, steering column and attaching parts, steering column assembly, steering control unit, steer tires and wheels
• Brake System – brake cooling system, brake linkage single pedal and dual pedal, wet brake booster, master cylinder and attaching parts, brake master cylinder assembly, park brake assembly (one cable NMHG and two cable Dana)
• Hydraulic System – hydraulic supply and return, hydraulic supply group, hydraulic filter, gear pump, hydraulic breather, hand levers for three and four function, manual control valve lockout group, hydraulic control valve (manual and electro-hydraulic), tilt cylinder and installation, tilt hoses, auxiliary hoses, vent line group, hoist hose
• Mast – Two Stage Limited Free-Lift – outer mast, inner mast, main lift, main lift cylinder, header hose, carriage, auxiliary tube extensions
• Mast – Two Stage Full Free-Lift – outer mast and main lift, inner mast and free-lift, main lift cylinder, free-lift cylinder, header hose, carriage, auxiliary tube extensions
• Mast – Three Stage Full Free-Lift – outer mast, inner mast, intermediate mast, main lift, main lift cylinder, free-lift, free-lift cylinder, header hose, carriage, auxiliary tube extensions
• Options – bolt-on fenders, strobe light, dual mirrors, rear mounted mirror, fire extinguisher, back-up alarm, pressure regulator, GM LPG regulator drain kit, accumulator, integral side-shift and integral side-shift carriages
• Field Conversion Kits – add-on option kits, audible alarm kits, E-hydraulic control conversion kits, manual hydraulic control conversion kits, header hose conversion kits, auxiliary tube extension kit, light kits, LED lights, seat conversion kits, direction control conversion
• Numerical Index – complete part number lookup with page and item references
• Special Equipment Design – light package, approval UL, seat belt variants

What This Hyster S120FT Parts Manual Delivers

When you are staring at a worn hydraulic valve, a cracked exhaust manifold, or a damaged mast chain, you do not have time to guess at part numbers. This Hyster S120FT parts manual removes the guesswork. Every assembly is drawn in exploded view and every part is called out with its factory part number, description, and the quantity required for one assembly. Whether you are rebuilding a dual speed transmission, replacing a wet brake carrier, or ordering a complete cylinder head assembly for a GM 4.3L LPG engine, the illustration and parts list sit side by side on the same page, so you can point to the exact item you need and read off the number.

The manual is serial-number specific to H004V01886L, and the introduction explains how to use the keys, footnotes, and serial number breaks to select the correct part for your truck’s build date. Where a truck may contain non-production or special content, the parts list marks those items and directs you to the Special Equipment Design section at the back. The numerical index at the end lets you find any part number directly and jump straight to the page and item number where it appears.

Systems Covered in Detail

The Hyster S120FT H004 parts manual spans every system that keeps a forklift working. On the engine side, both the GM 4.3L and GM 3.4L gasoline and LPG options are broken down – cylinder block, cylinder head, camshaft, oil pan, intake manifold, exhaust manifolds, water pump, thermostat housing, fan mount, flywheel, and the complete LPG conversion hardware including regulator, mixer, converter, and lock-off. The fuel system coverage includes air cleaner assemblies, pre-cleaners, fuel pumps, fuel filters, and tank brackets for swing-out and drop-down LPG tanks.

The electrical section is equally deep: engine control modules and sensors, fuse boxes, sealed alternators, starters, distributors, spark plug wiring, battery cables, remote key switches, instrument clusters, impact sensors, and full chassis and cowl wire harnesses for both manual and electro-hydraulic hydraulics. Mini-lever control modules for three-, four-, and five-function arrangements are illustrated with every lever, button, switch, and printed circuit board called out.

Transmission coverage handles single speed and dual speed T139 and T150 units, including the torque converter, forward and reverse clutch packs, control valve assembly, cooling hoses, and mount. The drive axle section covers both NMHG and Dana wet brake axles – differentials, axle housings, hubs, wheel bearings, planetary carriers, brake assemblies, and park brake hardware. Steering, brake, and hydraulic systems each get their own section, from steer axle spindles and cylinders to master cylinders, wet brake boosters, gear pumps, hydraulic filters, and the complete range of manual and electro-hydraulic control valves.

Masts, Carriages, and Attachments

Three dedicated mast sections cover two-stage limited free-lift, two-stage full free-lift, and three-stage full free-lift configurations. Each section includes outer mast, inner mast, intermediate mast where applicable, main lift cylinders, free-lift cylinders, header hoses, chain and sheave assemblies, load rollers, and carriages. The options section adds integral side-shift carriages for Class III and Class IV, in 1067 mm (42 in.) and 1219 mm (48 in.) widths, plus the hose routing and auxiliary tube extensions to feed them.

If your truck is fitted with an integral side-shift, the manual gives you the complete carriage frame breakdown – wear strips, grease fittings, seals, bushings, rod wipers, snap rings, rods, and aprons – so you can rebuild the side-shift rather than replace it. Auxiliary tube extensions are documented for standard carriage, integral side-shift carriage, and attachment carriage, with separate part numbers for three-function and four-function hydraulics, and for manual or E-hydraulic quick-disconnect fittings.

Options and Field Conversion Kits

The options and field conversion kit sections matter if you are adding equipment to an existing truck or updating an older configuration. Bolt-on fenders, dual mirrors, rear-mounted mirrors, LED strobe lights, fire extinguishers, back-up alarms, pressure regulators, and accumulators are all covered. Field conversion kits include header hose conversion kits for two-stage limited free-lift, two-stage full free-lift, and three-stage full free-lift masts, E-hydraulic and manual hydraulic control conversion kits, auxiliary tube extension kits, and seat conversion kits for full suspension swivel and non-swivel seats.

Why This Hyster S120FT Parts Manual Belongs in Your Workshop

Ordering the wrong part costs you a second shipment, a second teardown, and a machine sitting idle. The Hyster S120FT (H004) parts manual gives you the factory illustration and the factory part number on the same page, so you can verify what you are looking at before you pick up the phone. The serial number breaks, ECN references, and footnotes tell you which part applies to your specific truck, and the keys let you match the right quantity column to your configuration.

This is the same parts catalog a Hyster dealer uses to look up replacement components. With 634 pages and full coverage of the S80FT, S100FT, and S120FT trucks, it is a working reference you will return to every time a customer asks for a price, a part becomes obsolete, or a rebuild needs a seal kit that is not obvious from the outside.

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Instant PDF Delivery

Your Hyster S120FT H004 parts manual is delivered as an instant PDF download after checkout. There is no shipping, no waiting for a disc, and no bulky binder taking up shelf space. Open it on a laptop in the shop, a tablet on the shop floor, or a phone at the parts counter – then print the pages you need and take them to the machine. Search the numerical index, jump to the figure you need, and keep the whole parts catalog within reach whenever you are ordering or rebuilding.