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Hyster S70-100XM; S80-100XMBCS; S120XMS; S100XM-PRS (F004) Parts Manual – PDF DOWNLOAD
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Hyster S70-100XM; S80-100XMBCS; S120XMS; S100XM-PRS (F004) Parts Manual – PDF DOWNLOAD
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Description
Hyster S70-100XM; S80-100XMBCS; S120XMS; S100XM-PRS (F004) Parts Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster S70-100XM; S80-100XMBCS; S120XMS; S100XM-PRS (F004) 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 14-1) 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 14-1) 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 S70-100XM; S80-100XMBCS; S120XMS; S100XM-PRS (F004) Parts Manual – PDF DOWNLOAD
Frame............................................................................................... 19 GENERAL TRUCK................................................................................... 22 FLOOR PLATES AND COVERS......................................................................... 24 HOOD............................................................................................ 28 BATTERY TRAY LATCH.............................................................................. 31 COUNTERWEIGHT................................................................................... 34 OVERHEAD GUARD.................................................................................. 36 NON-SUSPENSION SEAT............................................................................. 38 NON-SUSPENSION SEAT............................................................................. 40 FULL SUSPENSION SEAT SHEET 1 OF 2 (→ S/N F004V03917C) ......................................... 42 FULL SUSPENSION SEAT SHEET 2 OF 2 (→ S/N F004V03917C) ......................................... 46 FULL SUSPENSION SEAT............................................................................ 48 FULL SUSPENSION SWIVEL SEAT SHEET 1 OF 2 (→ S/N F004V03917C) .................................. 50 FULL SUSPENSION SWIVEL SEAT SHEET 2 OF 2 (→ S/N F004V03917C) .................................. 54 FULL SUSPENSION SWIVEL SEAT..................................................................... 58 LABELS.......................................................................................... 60 FORK STANDARD TAPER HOOK TYPE (S70-80XM)........................................................ 62 FORK STANDARD TAPER HOOK TYPE (S100-120XM)...................................................... 63 FORK POLISHED WITH FULL BOTTOM TAPER HOOK TYPE.................................................. 64 LOAD BACKREST EXTENSION......................................................................... 66 ENGINES............................................................................................. 69 ASSEMBLED ENGINE GASOLINE, 4.3L EPA COMPLIANT - SHEET 1 OF 2 ................................... 74 ASSEMBLED ENGINE GASOLINE, 4.3L EPA COMPLIANT - SHEET 2 OF 2 ................................... 76 ASSEMBLED ENGINE LPG, 4.3L EPA COMPLIANT - SHEET 1 OF 2 ........................................ 80 ASSEMBLED ENGINE LPG, 4.3L EPA COMPLIANT - SHEET 2 OF 2 ........................................ 82 COIL ASSEMBLY................................................................................... 85 VALVE COVER AND INLET MANIFOLD GASOLINE AND LPG................................................. 86 CYLINDER HEAD GASOLINE AND LPG.................................................................. 90 CYLINDER BLOCK GASOLINE AND LPG................................................................. 92 INTAKE MANIFOLD AND FUEL RAIL GASOLINE - 4.3L EPA COMPLIANT .................................... 94 CAMSHAFT AND OIL PAN GASOLINE AND LPG........................................................... 96 OIL PUMP GASOLINE AND LPG.......................................................................100 DRIP SHIELD GASOLINE AND LPG....................................................................102 COOLING GASOLINE AND LPG........................................................................104 FAN DRIVE AND ALTERNATOR MOUNTING GASOLINE AND LPG..............................................108 VALVE COVER AND ROCKER ARM SHAFT DIESEL.........................................................110 CYLINDER HEAD DIESEL............................................................................112 CYLINDER BLOCK DIESEL...........................................................................114 MANIFOLDS DIESEL................................................................................116 CRANKSHAFT AND PISTON DIESEL....................................................................118 OIL PAN AND PUMP DIESEL.........................................................................120 OIL FILTER DIESEL...............................................................................123 COOLING DIESEL..................................................................................124 COOLANT PUMP DIESEL.............................................................................126 TIMING GEAR DIESEL..............................................................................128 ENGINE MOUNTS...................................................................................130 FLYWHEEL HOUSING GASOLINE, LPG AND DIESEL.......................................................132 EXHAUST GASOLINE AND LPG (STANDARD, OVERHEAD AND SAFETY), DIESEL (OVERHEAD) - EPA COMPLIANT ....134 EXHAUST WRAPS PAPER INDUSTRY OPTION.............................................................136 EXHAUST DIESEL - STANDARD ......................................................................138 EXHAUSTER ROTARY - DIESEL ......................................................................140 EXHAUST GASOLINE AND LPG - NON-EPA COMPLIANT ...................................................142 FUEL SYSTEM.........................................................................................145 AIR INTAKE AND FILTER SYSTEM GASOLINE, LPG AND DIESEL...........................................148 AIR FILTER......................................................................................150 FUEL SUPPLY SYSTEM GASOLINE.....................................................................152 THROTTLE BODY ASSEMBLY GASOLINE - 4.3L EPA COMPLIANT ENGINE ....................................154 ENGINE FUEL SYSTEM LPG - 4.3L EPA COMPLIANT ENGINE .............................................156 FUEL FILTERING SYSTEM LPG - 4.3L EPA COMPLIANT ENGINE ..........................................158 THROTTLE BODY AND MIXER LPG - 4.3L EPA COMPLIANT ENGINE ........................................160 REGULATING SYSTEM LPG - 4.3L EPA COMPLIANT ENGINE ..............................................162 LPG TANK BRACKET FIXED - STANDARD (→ S/N F004V02383B) ........................................164 LPG TANK BRACKET FIXED - STANDARD (S/N F004V02384B →) ........................................166 LPG TANK BRACKET EZXCHANGE BRACKET - STANDARD AND BOX CAR SPECIAL (→ S/N F004V02383B) ........168 LPG TANK BRACKET EZXCHANGE BRACKET - STANDARD AND BOX CAR SPECIAL (S/N F004V02384B →) ........172 LPG TANK BRACKET FIXED - BOX CAR SPECIAL .......................................................175 LPG TANK BRACKET EZXCHANGE BRACKET - 80 BOX CAR SPECIAL ........................................176 LPG TANK BRACKET EZXCHANGE BRACKET - 80 BOX CAR SPECIAL (1/2005 →) ...........................178 LPG TANK BRACKET FIXED - STANDARD WITH NYLON STRAP .............................................181 LPG TANK BRACKET FIXED - BOX CAR SPECIAL WITH NYLON STRAP ......................................183 LPG TANK BRACKET EZXCHANGE BRACKET - 80 BOX CAR SPECIAL WITH NYLON STRAP .......................184 FUEL SUPPLY SYSTEM DIESEL.......................................................................188 FUEL SYSTEM LOW PRESSURE - DIESEL ..............................................................190 HIGH PRESSURE FUEL INJECTION DIESEL.............................................................192 WATER SEPARATOR DIESEL..........................................................................194 LIFT PUMP DIESEL................................................................................196 FUEL FILTER DIESEL..............................................................................197 THROTTLE LINKAGE GASOLINE, LPG, AND DIESEL......................................................198 ACCELERATOR PEDAL AND BRACKET ASSEMBLY WITH FORWARD AND REVERSE LEVER...........................200 ACCELERATOR PEDAL AND BRACKET ASSEMBLY MONOTROL.................................................202 MONOTROL PEDAL..................................................................................204 ELECTRICAL SYSTEM...................................................................................207 INSTRUMENT PANEL................................................................................210 ELECTRICAL SYSTEM DASH PANEL....................................................................212 ELECTRICAL SYSTEM GASOLINE AND LPG..............................................................216 ELECTRICAL SYSTEM LPS...........................................................................220 ELECTRICAL SYSTEM DIESEL........................................................................222 ELECTRICAL SYSTEM CHASSIS.......................................................................226 WIRE HARNESS DASH (→ S/N F004V01696B) .........................................................228 WIRE HARNESS DASH (S/N F004V01697B ↔ S/N F004V03148C) .........................................230 WIRE HARNESS DASH (S/N F004V03149C →) .........................................................232 WIRE HARNESS POWER DISTRIBUTION GROUP...........................................................236 WIRE HARNESS CHASSIS (→ S/N F004V03917C) ......................................................240 WIRE HARNESS CHASSIS (S/N F004V03918C →) ......................................................242 WIRE HARNESS FUEL INJECTOR - GASOLINE GM 4.3L ..................................................245 WIRE HARNESS ENGINE, GASOLINE GM 4.3L - SHEET 1 0F 2 ...........................................248 WIRE HARNESS ENGINE, GASOLINE GM 4.3L - SHEET 2 OF 2 ...........................................250 WIRE HARNESS - ENGINE LPG GM 4.3L - SHEET 1 0F 2 ...............................................252 WIRE HARNESS - ENGINE LPG GM 4.3L - SHEET 2 OF 2 ...............................................256 WIRE HARNESS LPG REGULATOR......................................................................258 WIRE HARNESS ENGINE - DIESEL ...................................................................260 WIRE HARNESS INTERFACE..........................................................................264 WIRE HARNESS SEALED ALTERNATOR..................................................................266 DISTRIBUTOR GASOLINE AND LPG....................................................................268 SEALED ALTERNATOR...............................................................................270 ALTERNATOR MOUNTING DIESEL......................................................................272 STARTER GASOLINE AND LPG........................................................................274 STARTER DIESEL..................................................................................276 STARTER DIESEL - OPTIONAL ......................................................................278 TRANSMISSION........................................................................................281 TRANSMISSION....................................................................................284 TRANSMISSION CONTROL VALVE SHEET 1 OF 2.........................................................288 TRANSMISSION CONTROL VALVE SHEET 2 OF 2.........................................................290 CLUTCH PACKS....................................................................................292 CLUTCH PACKS....................................................................................294 TORQUE CONVERTER................................................................................296 DIFFERENTIAL AND HYPOID ASSEMBLY................................................................298 DIFFERENTIAL AND HYPOID ASSEMBLY................................................................300 DRIVE AXLE......................................................................................302 DRIVE TIRES AND WHEELS..........................................................................305 STEERING SYSTEM.....................................................................................307 STEER COLUMN....................................................................................310 SHIFT LEVERS....................................................................................312 STEER AXLE......................................................................................314 STEER CYLINDER..................................................................................318 STEERING CYLINDER...............................................................................320 STEER TIRES AND WHEELS..........................................................................322 BRAKE SYSTEM........................................................................................323 BRAKE LINKAGE SINGLE PEDAL......................................................................326 BRAKE LINKAGE DUAL PEDALS.......................................................................328 BRAKE LINES.....................................................................................330 MASTER CYLINDER AND BRAKE BOOSTER...............................................................332 PARK BRAKE LEVER................................................................................334 BRAKE ASSEMBLY SHORT WHEEL BASE.................................................................336 BRAKE ASSEMBLY LONG WHEEL BASE..................................................................338 BRAKE ASSEMBLY OPTIONAL 4 INCH (100 MM) WIDE....................................................340 HYDRAULIC SYSTEM....................................................................................343 HYDRAULIC HOSES AND FITTINGS SUPPLY AND RETURN..................................................346 HYDRAULIC HOSES AND FITTINGS TILT...............................................................348 HYDRAULIC HOSES AND FITTINGS AUXILIARY - 3, 4 AND 5 FUNCTION ...................................350 HYDRAULIC HOSE AND FITTINGS STEERING AND HOIST..................................................352 CONTROL VALVE AND ATTACHING PARTS THREE FUNCTION (→ S/N F004V02247B) ..........................354 CONTROL VALVE AND ATTACHING PARTS FOUR FUNCTION (→ S/N F004V02247B) ...........................358 CONTROL VALVE AND ATTACHING PARTS FIVE FUNCTION (→ S/N F004V02247B) ...........................362 HYDRAULIC CONTROL VALVE.........................................................................366 CONTROL VALVE AND ATTACHING PARTS THREE FUNCTION (S/N F004V02148B →) ..........................370 CONTROL VALVE AND ATTACHING PARTS FOUR FUNCTION (S/N F004V02248B →) ...........................374 CONTROL VALVE AND ATTACHING PARTS FIVE FUNCTION (S/N F004V02248B →) ...........................378 HYDRAULIC CONTROL VALVE THREE, FOUR, AND FIVE FUNCTION (S/N F004V02161B →) ....................382 TRANSMISSION COOLING AND STEERING LINES.........................................................386 HYDRAULIC FILTER HOUSING........................................................................388 HYDRAULIC PUMP..................................................................................390 TILT CYLINDER...................................................................................391 MAST INSTALLATION...............................................................................394 PRESSURE REGULATOR USED WITH PAPER ROLL.........................................................396 Mast-Two Stage Limited Free-Lift....................................................................399 OUTER MAST TWO STAGE FULL FREE-LIFT.............................................................402 INNER MAST TWO STAGE LIMITED FREE-LIFT..........................................................404 MAIN LIFT TWO STAGE LIMITED FREE-LIFT...........................................................406 MAIN CYLINDER TWO STAGE LIMITED FREE-LIFT - S70-80XM ...........................................410 MAIN CYLINDER TWO STAGE LIMITED FREE-LIFT - S100-120XM .........................................412 HEADER HOSE TWO STAGE LIMITED FREE-LIFT.........................................................414 CARRIAGE TWO STAGE LIMITED FREE-LIFT............................................................418 Mast-Two Stage Full Free-Lift.......................................................................421 OUTER MAST AND MAIN LIFT TWO STAGE FULL FREE-LIFT...............................................424 INNER MAST AND FREE-LIFT TWO STAGE FULL FREE-LIFT...............................................428 MAIN CYLINDER TWO STAGE FULL FREE-LIFT - S70-80XM ..............................................432 MAIN CYLINDER TWO STAGE FULL FREE-LIFT - S100-120XM ............................................436 FREE-LIFT CYLINDER TWO STAGE FULL FREE-LIFT.....................................................440 HEADER HOSE TWO STAGE FULL FREE-LIFT............................................................444 CARRIAGE TWO STAGE FULL FREE-LIFT...............................................................450 Mast-Three Stage Full Free-Lift.....................................................................453 OUTER MAST THREE STAGE FULL FREE-LIFT...........................................................456 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT....................................................460 INNER MAST THREE STAGE FULL FREE-LIFT...........................................................464 MAIN LIFT THREE STAGE FULL FREE-LIFT............................................................466 FREE-LIFT THREE STAGE FULL FREE-LIFT............................................................470 MAIN CYLINDER THREE STAGE FULL FREE-LIFT........................................................474 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT...................................................478 HEADER HOSE THREE STAGE FULL FREE-LIFT..........................................................482 CARRIAGE THREE STAGE FULL FREE-LIFT.............................................................486 OPTIONS.............................................................................................489 INTEGRAL SIDE-SHIFT TWO STAGE LIMITED FREE-LIFT - S70-80XM .....................................492 INTEGRAL SIDE-SHIFT TWO STAGE LIMITED FREE-LIFT - S100-120XM ...................................494 INTEGRAL SIDE-SHIFT CARRIAGE 1067 MM (42 IN.) CLASS III - TWO STAGE LIMITED FREE-LIFT ..........496 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS III - TWO STAGE LIMITED FREE-LIFT ..........498 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS IV - TWO STAGE LIMITED FREE-LIFT ...........500 INTEGRAL SIDE-SHIFT TWO STAGE FULL FREE-LIFT - S70-80XM ........................................502 INTEGRAL SIDE-SHIFT TWO STAGE FULL FREE-LIFT - S100-120XM ......................................504 INTEGRAL SIDE-SHIFT CARRIAGE 1067 MM (42 IN.) CLASS III - TWO STAGE FULL FREE-LIFT .............506 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS III - TWO STAGE FULL FREE-LIFT .............508 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS IV - TWO STAGE FULL FREE-LIFT ..............510 INTEGRAL SIDE-SHIFT THREE STAGE FULL FREE-LIFT - S70-80XM ......................................512 INTEGRAL SIDE-SHIFT THREE STAGE FULL FREE-LIFT - S100-120XM ....................................514 INTEGRAL SIDE-SHIFT CARRIAGE 1067 MM (42 IN.) CLASS III - THREE STAGE FULL FREE-LIFT ...........516 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS III - THREE STAGE FULL FREE-LIFT ...........518 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS IV - THREE STAGE FULL FREE-LIFT ............520 AUXILIARY TUBE EXTENSION KIT TWO STAGE LIMITED FREE-LIFT........................................522 TUBE EXTENSION KITS TWO AND THREE STAGE FULL FREE-LIFT..........................................524 QUICK DISCONNECT................................................................................526 FRONT HEADLIGHTS................................................................................528 REAR DRIVE LIGHT................................................................................530 PLUGS WITHOUT BACK-UP AND BRAKE LIGHTS..........................................................532 LIGHTS, LED BACK-UP AND BRAKE...................................................................534 WIRE HARNESS PRESSURE SWITCH - LED BRAKE LIGHTS ................................................536 LIGHTS BACK-UP AND BRAKE WITHOUT HEAVY DUTY AIR INTAKE OR OVERHEAD EXHAUST......................538 LIGHTS REAR DRIVE, BACK-UP AND BRAKE WITH HEAVY DUTY AIR INTAKE - OR OVERHEAD EXHAUST ..........540 LED LIGHTS, BACK-UP AND BRAKE WITH HEAVY DUTY AIR INTAKE AND OVERHEAD EXHAUST...................542 STROBE LIGHT HIGH MOUNT.........................................................................544 STROBE LIGHT LOW MOUNT..........................................................................546 ACCUMULATOR.....................................................................................548 BACK-UP ALARM...................................................................................549 FIELD CONVERSION KITS...............................................................................551 MISCELLANEOUS KITS..............................................................................554 HYDRAULIC CONTROL CONVERSIONS HUSCO VALVES ONLY.................................................554 SWING OUT DROP DOWN LPG KITS....................................................................554 OPERATOR PRESENCE SYSTEM KITS...................................................................554 TUBE EXTENSION CONVERSION KITS TWO STAGE LIMITED FREE-LIFT......................................554 TUBE EXTENSION CONVERSION KITS THREE STAGE FULL FREE-LIFT.......................................555 TUBE EXTENSION CONVERSION KITS TWO STAGE FULL FREE-LIFT.........................................555 NUMERICAL INDEX.....................................................................................557
HYSTER S70-100XM; S80-100XMBCS; S120XMS; S100XM-PRS (F004) PARTS MANUAL – PDF DOWNLOAD:
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