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Hyster S120FTS - User Manual

Hyster S120FTS
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Hyster J004 (S80FT, S80FT-BCS, S100FT, S100FT-BCS,
S120FT, S120FTS, S120FT-PRS) Forklift Service Repair
Manual
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Summary

Safety Precautions Maintenance and Repair

Safe Handling and Operation

Covers safe lifting, manual handling avoidance, wearing safety glasses, and maintaining cleanliness.

Unit Security and Repair Procedures

Emphasizes using blocks, approved parts, fastener removal, battery disconnection, and "Do Not Operate" tags.

Fuel and Battery Safety

Focuses on safe handling of flammable fuels and precautions during battery charging.

Safety Symbol Definitions

Explains WARNING and CAUTION symbols and their associated color coding for hazard identification.

General Information About Diagrams and Schematics

Vehicle Wiring Standards

Chassis wiring conforms to ES-1359 standard, utilizing colors and marked circuit numbers.

Wire Color Variations

Wire colors may vary for MONOTROL®, engine harnesses, and sensor wiring.

Color Viewing and B&W Interpretation

Diagrams can be viewed in color; refer to schematic identification for B&W interpretation.

Symbol Definitions

Type S Symbol Definition

Identifies information for UL Safety rated trucks, applicable to GS, LPS, and DS depending on fuel type.

Schematic Navigation Symbols

Explains Arrow and Dashed Line symbols for navigating schematics and diagrams.

Summary

Safety Precautions Maintenance and Repair

Safe Handling and Operation

Covers safe lifting, manual handling avoidance, wearing safety glasses, and maintaining cleanliness.

Unit Security and Repair Procedures

Emphasizes using blocks, approved parts, fastener removal, battery disconnection, and "Do Not Operate" tags.

Fuel and Battery Safety

Focuses on safe handling of flammable fuels and precautions during battery charging.

Safety Symbol Definitions

Explains WARNING and CAUTION symbols and their associated color coding for hazard identification.

General Information About Diagrams and Schematics

Vehicle Wiring Standards

Chassis wiring conforms to ES-1359 standard, utilizing colors and marked circuit numbers.

Wire Color Variations

Wire colors may vary for MONOTROL®, engine harnesses, and sensor wiring.

Color Viewing and B&W Interpretation

Diagrams can be viewed in color; refer to schematic identification for B&W interpretation.

Symbol Definitions

Type S Symbol Definition

Identifies information for UL Safety rated trucks, applicable to GS, LPS, and DS depending on fuel type.

Schematic Navigation Symbols

Explains Arrow and Dashed Line symbols for navigating schematics and diagrams.

Overview

This document is a service and repair manual for Hyster J004 (S80FT, S80FT-BCS, S100FT, S100FT-BCS, S120FT, S120FTS, S120FT-PRS) forklift trucks. It also covers diagrams and schematics for Hyster H4.0FT5, H4.0FT6, H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) [U005]; S4.0-5.5FT, S5.5FTS (S80-120FT, S80-100FTBCS, S120FTS, S120STPRS) [J004]; and H6.0-7.0FT (H135-155FT) [L006] models.

The manual provides general guidelines for maintenance and service, intended for use by trained and experienced technicians. It emphasizes safety precautions, including disconnecting the battery connector before maintenance, using correct blocks to prevent rolling or falling, wearing safety glasses, and using proper lifting mechanisms for heavy parts.

Function Description:

The Hyster J004 series forklifts are industrial trucks designed for lifting and transporting materials. The manual focuses on the electrical systems of these forklifts, providing detailed diagrams and schematics to aid in troubleshooting and repair. The electrical system includes components for battery power, ignition, engine control (for both LPG and Diesel engines), and various sensors and actuators. The manual covers different engine types, including PSI 2.0/2.4L LPG, PSI 2.0/2.4L Bi-Fuel, PSI 4.3L Gas, Kubota 2.5L LPG, Yanmar 2.6L, 3.0L & 3.3L DSL, Kubota 3.6L DSL T3 57 & 62kW, and Cummins 3.3L T3 110HP DSL engines, indicating a versatile range of power options for the forklifts.

Important Technical Specifications (Derived from Schematics and Tables):

  • Electrical Circuit Identification: Conforms to electrical circuit identification standard ES-1359.
  • Wire Colors and Functions:
    • Red: Battery-level power circuits and 5 volt supply circuits.
    • Black: Heavy current grounds.
    • Green: Signal grounds.
    • White: Other circuits.
    • Twisted Pair (Yellow/Green): CANbus CAN-Hi CAN-Lo.
    • Twisted Pair (Dk Blue/Pink and Dk Blue/White): CANbus (Mazda) CAN-Hi CAN-Lo.
  • VSM BUS Lettering:
    • R: Regulated Output Voltage.
    • D: Driver.
    • I: Input.
  • Fuses: Various fuse ratings are indicated in the schematics, such as 20A, 25A, 30A for PDM (Power Distribution Module) circuits, 70A for starter circuits, 5A for specific IGN circuits, 10A for fuel pump circuits, and 100A for main starter circuits.
  • Engine Control Modules (ECU): The CRS202 ECU is a central component, with connections for various sensors and actuators, including:
    • 5V EXT and 5V RTN for sensor power.
    • CANbus connections (CAN1+, CAN1-, CAN2+, CAN2-).
    • Inputs for Accelerator Pedal (ACC PED A, ACC PED B), Fuel Pressure (DIL_PRESS), Crank Sensor (CRANK+, CRANK-), Engine Coolant Temperature (ECT), Intake Air Temperature (IAT), Manifold Absolute Pressure (MAP), Throttle Position Sensor (TPS1, TPS2), and various auxiliary digital and analog inputs.
    • Outputs for Ignition Coils (SPARK COIL 1A, 1B, 2A, 2B), Fuel Injectors (INJ1_LS to INJ6_LS), and PWM signals.
  • Sensors and Actuators:
    • LPG/Bi-Fuel Systems: Fuel Pressure Manifold Sensor (CPS254), Fuel Level Sensor, Fuel Pump (CPS207), LPG Lock-Off (CPS275), Air Filter Switch, LPG Optical Sensor, Low LPG Switch, Oxygen Sensors (EGO 1, EGO 2), Crank Sensor (CPS225), Engine Coolant Temp (CPS232), TMAP (CPS212), Throttle (CPS230).
    • Diesel Systems: Glow Plug Relay, Fuel Shutoff, Cold Start Aid, Water Temp Sensor, DIL Pressure Sensor, Engine RPM Sensor, TPS, Fuel Filter Water Separator Sensor, Barometric Pressure Sensor, IAT/IAP Sensor, Cam Sensor, Coolant Level Sensor.
  • Diagnostic Port: J1939 diagnostic connections are present for communication with diagnostic tools.

Usage Features:

The forklifts are designed for various applications, indicated by the model designations (e.g., S80FT, S120FT-PRS). The inclusion of different engine types (LPG, Bi-Fuel, Gas, Diesel) suggests adaptability to diverse operational environments and fuel availability. The "Type S" symbol indicates information for UL Safety rated trucks, applicable for GS, LPS, and DS ratings depending on fuel type, highlighting safety compliance for specific operating conditions. The presence of features like impact sensors and steer wheel horn buttons indicates a focus on operator safety and awareness.

Maintenance Features:

  • Regular Updates: Service Manuals are regularly updated, and technicians are advised to check with authorized Hyster® dealers for the latest technical service information.
  • Approved Parts: Emphasizes the use of "HYSTER APPROVED parts" for repairs, ensuring replacement parts meet or exceed original equipment manufacturer specifications.
  • Safety Procedures: Detailed safety precautions are provided, including disconnecting power, using proper blocking, wearing safety glasses, and ensuring correct lifting practices.
  • Cleanliness: Stresses the importance of keeping the unit and working area clean and orderly.
  • Tool Usage: Recommends using correct, clean, and well-maintained tools.
  • Fasteners: Advises ensuring all nuts, bolts, snap rings, and other fastening devices are removed before applying force to remove parts.
  • Warning Tags: Requires fastening a "DO NOT OPERATE" tag to controls when repairs are in progress or needed.
  • Fuel Handling: Specific safety precautions for handling flammable fuels (Gasoline, LPG, CNG, Diesel) and working on their systems.
  • Battery Safety: Warnings regarding flammable gas generated during battery charging, requiring fire/spark prevention and good ventilation.
  • Diagnostic Troubleshooting: Refers to a separate "Diagnostic Troubleshooting Manual" (9000SRM1112 Section 9030, Group 03) for further information, indicating a comprehensive diagnostic approach.
  • Color-Coded Schematics: Diagrams and schematics can be viewed and printed in color, aiding in identification of circuits. If not in color, circuit identification numbers are used. White chassis wires appear yellow in color versions.

Hyster S120FTS Specifications

General IconGeneral
ModelS120FTS
CategoryForklifts
Lift Capacity12000 lbs
Tire TypePneumatic
Fuel TypeDiesel
Fork Length48 inches

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