Complete service repair manual for Hyster E117 (H1050HD-CH, H1150HD-CH) Forklift Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster E117 (H1050HD-CH, H1150HD-CH) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Hyster E117 (H1050HD-CH, H1150HD-CH) Service Manual.pdf

Total Pages: 1,015 pages
File Format: PDF (Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

897948-1300SRM0634-(03-2005)-US-EN.pdf
897949-1300SRM0635-(06-2007)-US-EN.pdf
910072-1400SRM0046-(07-2007)-US-EN.pdf
910091-1900SRM0097-(07-2006)-US-EN.pdf
910442-8000SRM0231-(12-2004)-US-EN.pdf
1462736-5000SRM0723-(08-2005)-US-EN.pdf
1529749-1800SRM1036-(07-2007)-US-EN.pdf
1531822-1800SRM1038-(07-2007)-US-EN.pdf
1565180-1900SRM1102-(08-2004)-US-EN.pdf
1565181-2000SRM1108-(08-2004)-US-EN.pdf
1565182-1600SRM1109-(07-2007)-US-EN.pdf
1565183-2200SRM1110-(08-2004)-US-EN.pdf
1565184-0100SRM1111-(09-2006)-US-EN.pdf
1565582-1600SRM1114-(07-2007)-US-EN.pdf
1565653-2100SRM1116-(01-2007)-US-EN.pdf
1565789-1800SRM1117-(07-2007)-US-EN.pdf
1566270-0100SRM1118-(08-2004)-US-EN.pdf
1566278-8000SRM1154-(08-2005)-US-EN.pdf
1566279-8000SRM1155-(02-2005)-US-EN.pdf
1566449-1300SRM1156-(08-2004)-US-EN.pdf
1567897-8000SRM1153-(09-2005)-US-EN.pdf
1568204-0700SRM1159-(07-2007)-US-EN.pdf
1569718-4000SRM1160-(01-2007)-US-EN.pdf
1572882-8000SRM1173-(12-2005)-US-EN.pdf
1573930-0600SRM1172-(03-2005)-US-EN.pdf
1574068-1400SRM1171-(02-2008)-US-EN.pdf
1578950-2200SRM1119-(08-2004)-US-EN.pdf
Aurora_AC.pdf

    Extendable Container Attachment (Elme)...2
    Safety Precautions Maintenance and Repair...3
    General...8
    Description...8
    Operation...8
      Extend and Retract Circuit...10
      Twist Lock Circuit...10
      Seated Signal...10
      Slew Circuit...11
      Rotation Circuit...11
      Stop Cylinder...11
      Electrical System...11
        Fault Finding...12
      Additional Functions...12
        Automatic Locking...12
        Over Lowering Interrupt ...12
        Lift Interrupt...13
    Container Attachment Repair...13
      Remove...13
      Install...13
        Models 812/813...13
        Model 815...14
        Model 818...14
    Slew Cylinder Repair...14
      Remove...14
      Disassemble...15
      Clean...15
      Inspect...15
      Assemble...16
      Install...16
    Extension Cylinders Repair...16
      Remove...16
      Disassemble...18
      Clean...18
      Inspect...18
      Assemble...18
      Install...19
    Sideshift Cylinder Repair...19
      Remove...19
      Disassemble...20
      Clean...20
      Inspect...20
      Assemble...21
      Install...21
    Pendular Twist Locks Repair...21
      Disassemble...21
      Clean...22
      Inspect...22
      Assemble...23
    Fixed Twist lock Repair...24
      Remove...24
      Install...24
    Adjustments...25
      Twist Lock Angle Adjustments...25
      LOCKED/NOT LOCKED Proximity Switches Adjustment...25
      SEATED Signal Adjustment...26
    Maintenance...26
      General Maintenance...26
      Additional Spreader Maintenance...27
    Maintenance Schedule...27
      Container Attachment...27
    Torque Specifications...30
    Troubleshooting...30
  tables...2
    Table 1. Maintenance Schedule...28
    Table 2. ELME Schematic Overview...33
1529749-1800SRM1036-(07-2007)-US-EN...126
  toc...126
    Brake Accumulator...126
    Safety Precautions Maintenance and Repair...127
    General...130
    Description and Operation...130
    Accumulator Maintenance...130
      Precharge Check...130
      Precharge Filling...131
      Remove...132
      Disassemble...132
      Clean...134
      Inspect...134
      Repair...134
      Assemble...134
      Replace...134
  tables...126
    Table 1. Accumulator Pressures...131
1531822-1800SRM1038-(07-2007)-US-EN...138
  toc...138
    Service Brake...138
    Safety Precautions Maintenance and Repair...139
    General...142
    Description and Operation...142
      A917, E117, and F117 Only...142
      B222 Only...142
    Repair...144
      General...144
      Remove...144
        Drive Wheels and Tires...144
        Brake Housing...145
        Spindle and Brake Cover...147
      Disassemble...148
      Clean...150
        Ground and Polished Parts...150
        Parts With Rough Finish...150
        Wet Disc Brake and Axle Assembly...150
      Inspect...150
        Face Seals...150
        Disc...151
          Wear Limits...151
      Replace...151
        Parts...151
      Assemble...152
        Brake Housings...152
      Install...154
        Hub Oil Seals...154
          Double Seals...154
          Single Seal...155
        Spindle and Brake Cover...156
        Brake Housing...157
        Drive Wheels and Tires...160
      Pressure Switch...164
        Replace...164
      Accumulator...164
    Brake Pedal Valves (Treadle Valves) Repair...164
      All Models Except A917, B222, E117, and F117...164
        Remove...164
        Clean and Inspect...164
        Install...165
      A917, B222, E117, and F117...168
        Remove...168
        Clean and Inspect...168
        Install...168
    Brake System Air Removal...168
    Specifications...169
      Brake Coolant...172
        Coolant Change Intervals...172
          Normal Maintenance...172
      Hydraulic Fluid...172
    Troubleshooting...173
  tables...138
    Table 1. Friction Disc...151
    Table 2. Stationary Disc...151
    Table 3. Wheel Hub and Brake Housing Torque Chart...170
    Table 4. Brake Housing Cover Torque Chart...172
1565180-1900SRM1102-(08-2004)-US-EN...178
  toc...178
    Hydraulic System...178
    Safety Precautions Maintenance and Repair...179
    General...184
    Description and Operation...184
      Hydraulic Plate...184
      Hydraulic Pumps...185
      Cab Manifold...185
        Oil Cooled Brakes (Service Brakes)...185
        Lift/Tilt Functions...185
        Over Lower Interrupt...186
        Lift Interrupt...186
      Heat Exchanger System...186
      Steering Control System...186
      Brake System...186
    Hydraulic Pump Repair...187
      Remove...187
      Disassemble...187
        Tandem Gear Pump...187
        Tri-Section Gear Pump...187
      Clean and Inspect...188
      Assemble...189
        Tandem Gear Pump...189
        Tri-Section Gear Pump...190
      Install...190
      Pump Output Check...190
        First Method...190
        Second Method...191
    Cab Manifold...192
      Remove...192
      Disassemble Valves and Pressure Switches...193
      Clean and Inspect...193
      Assemble Valves and Pressure Switches...193
      Install...193
    Lift and Lower Circuit...195
      Description...195
      Operation...195
        Lift Circuit...196
        Lowering...196
        Lowering Control Valves...196
      Repairs...196
        General...196
        Remote Control Valve...197
          Description and Operation...197
          Remove...197
          Disassemble...197
          Clean and Inspect...198
          Assemble...198
          Install...199
          Adjust...199
        Lift Manifold...199
          Description and Operation...199
          Remove...199
          Clean and Inspect...199
          Assemble and Install...199
      Checks and Adjustments...201
    Tilt Control Circuit...202
      Description...202
      Operation...202
        Tilt/Lift Spool...203
        Relief Valves in Main Control Valve...203
        Relief Valves, Tilt Lock...203
      Repairs...203
        General...203
        Relief Valves, Tilt Lock, Disassemble...203
        Clean and Inspect...204
        Checks and Adjustments...204
    Attachment Circuit Valves...204
      General...204
        Selector Valves Auxiliary Functions...204
        Carriage Solenoid Valve...204
      Repairs...204
        Carriage Solenoid Valve...204
          Remove...204
          Disassemble...206
          Clean and Inspect...206
          Assemble...206
          Install...206
      Checks and Adjustments...206
    Other Hydraulic Components...207
      Description and Operation...207
        Relief Valves in Steering and Lift Circuits...207
        Reducer Valve...207
        Hydraulic Filters...207
      Hydraulic Filters...207
        Suction Filters...207
        High Pressure Filter...208
        Brake Filter...208
        Return Line Filters...209
      Hydraulic Hose Repair...210
      Checks and Adjustments...210
        Pilot Setting, Check...210
        Return Pressure, Check...210
        Main Function Relief Valve Pressure, Check...210
        Hydraulic Tank Breathers...211
    Specifications...212
      Hydraulic Pumps Output at 2100 rpm (Governed Speed)...212
        Cummins 290 Hp (216 kW) Engine...212
        Cummins 330 Hp (246 kW) Engine...212
      Relief Valves (Approximate Operating Pressures)...212
      Check Port Pressures...213
      Main Hydraulic Filters...213
      Tank Capacity...213
    Torque Specifications...213
      Remote Control Valves...213
      Attachment Control Valve...213
      Carriage Solenoid Valve...214
    Troubleshooting...214
      Lift and Lower Circuit...214
      Tilt Circuit...217
      Attachment Circuit Valves...219
      Attachment Control Valve...220
      Carriage Solenoid Valve...220
      Other Hydraulic Components...221
      Accumulator Circuit...221
      5 MPa ( 725 psi) Pilot Circuit...221
      Park Brake Circuit...222
  tables...178
    Table 1. Brake Treadle Settings...186
    Table 2. Gauge Ranges...210
    Table 3. Pressure Settings...211
1565181-2000SRM1108-(08-2004)-US-EN...230
  toc...230
    Hydraulic Plate...230
    Safety Precautions Maintenance and Repair...231
    General...234
    Description and Operation...235
      Hydraulic Oil Supply...235
      Manifold, Section 1 of Hydraulic Plate...235
      Main Control Valve, Section 2 of Hydraulic Plate...235
        Description...235
        Operation...236
          Auxiliary Section...236
          Tilt Section...236
          Lift Section...236
      Return Manifold, Section 3 of Hydraulic Plate...236
      Brake Manifold, Section 4 of Hydraulic Plate...240
        Cooling Circuit...240
        Service Brake...240
        Parking Brake...240
      Flow Amplifier, Section 5 of Hydraulic Plate...240
    Manifold, Section 1 of Hydraulic Plate...241
      General...241
      Valves and Pressure Switches...241
    Main Control Valve, Section 2 of Hydraulic Plate...244
      Remove...244
      Disassemble...244
        Auxiliary Section...244
        Lift Section...246
        Lift/Tilt Section...247
      Clean and Inspect...248
      Assemble...248
        Auxiliary Section...248
        Lift Section...248
        Lift/Tilt Section...249
      Install...249
    Return Manifold, Section 3 of Hydraulic Plate...250
      Remove...250
      Disassemble...250
      Clean and Inspect...251
      Assemble...251
      Install...251
    Brake Manifold, Section 4 of Hydraulic Plate...252
      Remove...252
      Clean and Inspect...252
      Install...252
    Flow Amplifier, Section 5 of Hydraulic Plate...253
    Hydraulic Hose Repair...253
    Hydraulic Hose Identification...253
    Torque Values...254
    Measurements and Adjustments...256
      Measurements...256
      Adjustments...256
    Troubleshooting...256
  tables...230
    Table 1. Pilot Hoses...254
    Table 2. Brake Hoses...254
    Table 3. Auxiliary Hoses With Alternating P and T...254
    Table 4. Steer Hoses...254
    Table 5. Pressure Settings at 2100 RPM...256
1565182-1600SRM1109-(07-2007)-US-EN...264
  toc...264
    Steering System...264
    Safety Precautions Maintenance and Repair...265
    General...268
    Description...268
    Steering Wheel and Column Assembly Repair...270
      General...270
      Steering Wheel and Horn...270
        Remove...270
        Install...270
    Steering Column...272
      Remove...272
      Install...272
    Steering Control Unit Repair...273
      General...273
      Description...273
      Operation...273
      Remove...273
      Disassemble...275
      Clean...278
      Assemble...278
      Install...284
    Steering System Air Removal...284
    Steering Relief Pressure Check and Adjustments...284
    Flow Amplifier Repair...286
      General...286
      Description...286
      Operation...286
        Neutral Position...286
        During Steering Function...286
        Manual Steering Function...288
      Disassemble...288
        Pressure Relief Valve...288
        End Cover at PP Port...288
        End Cover at LS Port...288
        Spools...289
        Directional Valve Spool...289
        Priority Valve Spool...289
        Pressure Control/Amplifier Valve Spool...289
        Check Valve...290
        Cushion/Suction Valves...290
      Clean...291
      Assemble...291
    Troubleshooting...292
1565183-2200SRM1110-(08-2004)-US-EN...296
  toc...296
    Instrument Panel Indicators and Senders...296
    Safety Precautions Maintenance and Repair...297
    General...300
    Description...300
      General...300
      Instrument Panel Meters, Indicators, and LCD Display...300
      Error Code Display...305
      Connector...307
        Seat Switch Logic...307
        Central Warning Light Output...309
        Buzzer Output...309
    Instrument Panel Component Replacement...311
      Instrument Panel...312
        Remove...312
      Light...312
        Replace...312
    Sender Replacement...313
      Fuel Level Sender...313
      Pressure Sender...313
      Temperature Sender...313
      Low Coolant Sender...314
      Vacuum Switch...314
      Crankshaft Position Sensor...315
  tables...296
    Table 1. Instrument Panel and Indicators...301
    Table 2. Switches Description...306
    Table 3. Pin Description...308
    Table 4. Sender Description...309
1565184-0100SRM1111-(09-2006)-US-EN...318
  toc...318
    Operator's Cab...318
    Safety Precautions Maintenance and Repair...319
    General...322
    Cab Repair...323
      Rear Cab Assembly...323
      Bottom Cab Assembly...324
      Cab Repair...324
        Remove...324
        Install...325
    Declutch (E117), Inching (F117), and Brake Pedals...326
      Brake Pedal, Adjust...326
      Declutch Pedal, Adjust (E117 Only)...326
      Inching Pedal, Adjust (F117 Only)...326
      Inching Pedal Sensor, Adjust (F117 Only)...326
    Throttle Pedal Sensor Adjustment...327
      Cable Alignment...327
        Engine Side...327
        Pedal Housing Side...327
      Check...328
      Adjust...328
    Seat Assembly Removal...328
    Power Assist Armrest...329
      Adjust...329
    Steering Column Repair...330
      Remove...330
      Install...330
    Window Wipers Replacement...331
      Window Wiper Assembly, Replace...331
      Front Window Wiper Motor Assembly, Replace...331
      Rear Window Wiper Motor Assembly, Replace...331
      Top Window Wiper Motor Assembly, Replace...332
    Window Washer Motors and Pumps...332
      Window Wiper and Washer Operating Switches...333
    Window Replacement...333
      Front Window, Replace...335
      Rear Window, Replace...335
      Top Window, Replace...335
      Door Window, Replace...335
    Heater and Air Conditioning Assembly...336
      Heater Parts, Replace...338
      Heat Control Knob/Switches...339
      Heat Control Knob/Cable...339
        Adjust...339
      Air Control Knob/Cable...340
        Adjust...340
      Air Filter, Replace...340
      Air Conditioning Condenser Fan(s)...341
        Remove...341
        Install...341
    Instruments, Switches, and Controls...341
      Switches...341
      Controls...342
    Fuses, Relays, And Power Sources...344
      Fuse Panel...344
      Fuses...345
      Relays...346
      Power Sources...347
    Label Replacement...347
1565582-1600SRM1114-(07-2007)-US-EN...350
  toc...350
    Steering Axle...350
    Safety Precautions Maintenance and Repair...351
    General...354
    Description...354
    How To Put Lift Truck On Blocks...355
      How to Lift Steer Tires...355
    Steering Axle Assembly...357
      Remove...357
      Install...358
    Wheels and Hubs...359
      Remove and Disassemble...359
      Clean...359
      Assemble and Install...360
    Spindles, Bearings, and Tie Rods...361
      Remove...361
      Install...362
    Steering Cylinder...364
      Remove and Disassemble...364
      Clean and Inspect...365
      Assemble and Install...365
    Torque Specifications...366
    Troubleshooting...366
1565653-2100SRM1116-(01-2007)-US-EN...370
  toc...370
    Tilt Cylinders...370
    Safety Precautions Maintenance and Repair...371
    General...374
    Description...374
    Tilt Cylinder Repair...374
      Remove...374
      Disassemble...376
      Clean...377
      Inspect...377
      Assemble...377
      Install...377
    Tilt Cylinder Leak Check...377
    Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...378
    Torque Specifications...379
    Troubleshooting...379
  tables...370
    Table 1. Movement Rate (Maximum) for Tilt Cylinders...378
1565789-1800SRM1117-(07-2007)-US-EN...382
  toc...382
    Parking Brake...382
    Safety Precautions Maintenance and Repair...383
    General...386
    Description and Operation...386
    Parking Brake Valve Replacement...386
      Remove...386
      Clean and Inspect...387
      Install...387
    Parking Brake Caliper Repair...387
      Remove...387
      Disassemble...387
      Inspect...387
      Install...388
      Bleed Brakes...390
      Adjust...390
    Brake Pad Repair...391
      Inspect...391
      Remove...391
      Install...392
    Seals Repair...392
      Remove...392
      Install...392
    Specifications...393
      Torque Requirements...393
      Wear Limits...393
      Lining to Disc Clearance...393
    Troubleshooting...394
  tables...382
    Table 1. Brake Pad Adjustment...391
    Table 2. Torque Requirements...393
    Table 3. Wear Limits...393
    Table 4. Lining to Disc Clearance...393
1566270-0100SRM1118-(08-2004)-US-EN...398
  toc...398
    Frame...398
    Safety Precautions Maintenance and Repair...399
    General...402
    Description...402
    Counterweight Repair...403
      Main Counterweight (Cast)...403
        Cover...403
          Remove...403
          Install...403
        Counterweight...403
          Remove...403
          Install...404
      Rear Counterweight (Cast)...405
        Remove...405
        Install...405
      Main Counterweight (Fabricated)...405
        Remove...405
        Install...405
    Covers...406
      Remove...406
      Install...407
    Floor Plates, Handrails, and Steps...408
    Hydraulic Tank Repair...409
      Remove...409
      Repair...411
        Small Leaks...411
        Large Leaks...411
      Clean...411
        Steam Method...411
        Chemical Solution Method...412
      Other Methods of Preparation for Repair...412
      Install...412
      Suction Filters and Inspection Cover...413
        Remove...413
        Clean and Inspect...414
        Install...414
    Fuel Tank Repair...414
      Remove...414
      Repair...416
      Install...416
    Engine Repair...416
      Remove...416
      Install...419
    Label Replacement...420
1566278-8000SRM1154-(08-2005)-US-EN...426
  toc...426
    Periodic Maintenance...426
    Safety Precautions Maintenance and Repair...427
    General...432
      Serial Number Data...432
      How to Move Disabled Lift Truck...432
        How to Tow Lift Truck...433
      How to Put Lift Truck on Blocks...433
        How to Raise Drive Tires...433
        How to Raise Steering Tires...434
    Maintenance Schedule...435
      Spreader Maintenance...443
    Maintenance Procedures Every 8 Hours or Daily...444
      How to Make Checks With Engine Stopped...444
        Safety Labels...444
        Operator Restraint System...444
          Safety Belt and Seat Rails...444
          Steering Column Latch...445
        Tires and Wheels...445
        Inspection of Mast and Lift Chains...446
        Drive Belt...446
        Crankcase Breather Tube...447
        Air Intake Piping and Charge Air Piping...447
        Cooling Fan...447
        Pre-Cleaner for Air Filter...448
        Fuel, Oil, or Coolant Leak Check...448
        Hydraulic Tank Breather...448
        Engine Oil...448
        Hydraulic System Oil...449
        Hydraulic High Pressure Oil Filter...450
        Battery...450
        Fuel Filter/Water Separator...451
      How to Add Fuel to Lift Truck...451
      How to Make Checks With Engine Running...452
        Gauges, Lights, Horn, Fuses, and Relays...452
          Sealed Fuses...453
        Transmission Oil...453
        Cooling System...454
        Engine Air Filter...454
        Engine Oil Pressure...454
        Electrical System...455
        Steering System...455
        Service Brakes...455
        Parking Brake...455
        Control Levers and Pedals...455
        Lift System Operation...455
        Attachments...455
    First Inspection After First 100 Hours of Operation...456
      Engine Oil Filter...456
      Drive Axle and Differential...456
      Lift Chains...456
      Transmission Oil Filter...456
      Air Conditioning...456
      Steer Wheel Hubs...456
    Maintenance Procedures Every 250 Hours Or Monthly...456
      Twist Locks...456
      Gantry Carriage and Container Attachments...457
    Maintenance Procedures Every 500 Hours or 3 Months...457
      Drive Belt...457
      Lift Chains...457
      Hydraulic Return Line Oil Filter...457
      Air Conditioning...457
      Wheel Nuts...458
      Heater Air Filter...458
      Steering Axle Kingpins...458
      Steering Axle Tie Rods...458
      Drive Shaft...458
      Steering Axle Pivots...458
      Mast and Carriage Load Rollers...458
      Mast Pivots, Sliding Surfaces...459
      Sideshift Carriage...459
    Maintenance Procedures Every 500 Hours or 6 Months...459
      Fuel Filter...459
      Engine Oil and Filter...459
      Oil Filter for Oil Cooled Brakes (Brake Filter)...459
      Change Transmission Oil...459
    Maintenance Procedures Every 1000 Hours or 6 Months...460
      Drive Axle and Differential Oil...460
      Service Brake System...460
      Brake System Accumulator...460
      Hub Bearings, Steer Wheels...460
      General Lubrication...460
    Maintenance Procedures Every 1500 Hours or 1 Year...460
      Engine...460
      Water Pump...460
      Turbocharger...460
      Engine Mounting Bolts...461
      Air Leaks, Air Intake and Exhaust...461
      Valve and Injector Adjustments...463
        General...463
        Adjust...464
          Injector Adjustment...464
          Valve Adjustment...465
    Maintenance Procedures Every 2000 Hours or 1 Year...467
      Hydraulic High Pressure Oil Filter...467
      Parking Brake Assembly...467
        Clean...468
        Inspect...468
    Maintenance Procedures Every 4000 Hours or 2 Years...469
      Hydraulic Suction Oil Filters...469
    Maintenance Procedures Every 5000 Hours...470
      Container Attachment...470
    Maintenance Procedures Every 6000 Hours or 2 Years...470
      Vibration Damper...470
      Fan Drive Idler Pulley...470
      Fan Hub...471
      Turbocharger...472
      Cooling System Fluid...472
    Safety Procedures When Working Near Mast...472
    Lift and Tilt System Leaks Check...474
      Lift System...474
      Tilt System...474
    Pneumatic Tires and Wheels...475
      Remove Wheels From Lift Truck...475
      Remove Tire From Wheel...475
        Remove Tire From Five-Piece Wheel...476
      Install Tire on Wheel...477
        Install Tire on Five-Piece Wheel...478
      Add Air Pressure to Tires...479
      Install Wheels on Lift Truck...480
  tables...426
    Table 1. Daily Inspections − Condition Check...436
    Table 2. Daily Inspections − Fluid Level Check...436
    Table 3. Daily Inspections − Checks With the Engine Running...437
    Table 4. First Inspection After First 100 Hours of Operation...438
    Table 5. Periodic Maintenance Schedule − Inspect and Adjust...439
    Table 6. Periodic Maintenance Schedule − Lubricate...441
    Table 7. Periodic Maintenance Schedule − Change...442
    Table 8. Container Attachment Maintenance - Lubricate...443
    Table 9. Container Attachment Maintenance − Replace...444
    Table 10. Valve and Injector Adjustment Specifications...463
    Table 11. Injector and Valve Measurement Sequence...464
1566279-8000SRM1155-(02-2005)-US-EN...484
  toc...484
    Capacities and Specifications...484
    Safety Precautions Maintenance and Repair...485
    Counterweight Weights...488
    Container Attachment Weights...488
    Carriage Weights...488
    Vehicle Weights...489
    Capacities...489
    Electrical System...489
    Engine Specifications (Cummins QSM 11)...490
    Mast Weights...490
    Lifting and Lowering Speeds...491
    Tires...491
    Hydraulic System Specifications...492
    Torque Specifications...493
      Control Valves...493
      Electrical System...493
      Counterweight (Cast)...493
      Counterweight (Fabricated)...493
      Counterweight (Slab)...493
      Drive Axle...493
      Wheel Bearing Adjusting Nut...493
      Differential...494
      Transmission...494
      Torque Converter...494
      Steering...494
      Wheel Nuts...494
      Carriages (All)...494
      Attachment - 20- to 40-Foot...494
  tables...484
    Table 1. Fabricated Type...488
    Table 2. Cast Type...488
1566449-1300SRM1156-(08-2004)-US-EN...498
  toc...498
    Four-Speed Powershift Transmission...498
    Safety Precautions Maintenance and Repair...499
    Description of Operation...502
      General...502
      Torque Convertor, Pump Drive, and Pressure Regulating Valve...502
      Input Shaft and Directional Clutches...502
      Range Clutches...503
      Output Section...505
      Transmission Controls...505
        Valve Operation...505
        Range Selection...505
      Electric Solenoid Controls...506
      Transmission Specifications...530
        Transmission Identification...530
        Weight, Dimensions, and Oil Capacity...530
    Automatic Powershift Control (APC 100)...531
      Transmission Control System...531
        Functional Description...532
        Fuses...534
      Transmission Control Lever...534
    Transmission Repair...535
      Remove...535
      Disassemble...537
        Transmission Case, Disassemble...537
        Torque Convertor Housing, Disassemble...557
        Reverse and Second-Speed Clutch...558
          Reverse Clutch, Disassemble...558
          Second-Speed Clutch, Disassemble...563
        Forward Clutch, Disassemble...566
        Low (First-Speed) Clutch, Disassemble...571
        Third-Speed Clutch, Disassemble...576
        Fourth-Speed Clutch, Disassemble...581
        Output Shaft, Disassemble...585
        Turbine Shaft, Disassemble...586
        Impeller and Oil Baffle, Disassemble...588
        Impeller Cover and Turbine, Disassemble...591
        Pump Drive Gear, Disassemble...592
      Clean and Inspect...593
        Housings...593
        Oil Seals and Gaskets...593
        Bearings...593
        Gears and Shafts...594
      Assemble...594
        Pump Drive Gear, Assemble...594
        Impeller Cover and Turbine, Assemble...595
        Impeller and Oil Baffle, Assemble...596
        Turbine Shaft, Assemble...599
        Output Shaft, Assemble...601
        Fourth Speed Clutch, Assemble...603
        Third-Speed Clutch, Assemble...607
        Low (First-Speed) Clutch, Assemble...612
        Forward Clutch, Assemble...619
        Reverse and Second-Speed Clutch...626
          Second-Speed Clutch, Assemble...626
          Reverse Clutch, Assemble...629
        Torque Convertor Housing, Assemble...634
        Transmission Case, Assemble...637
      Speed Sensor Installation...655
      Install...655
    Low (1st) Speed Shaft Bearing Adjustment...658
    Control Valve Repair...661
      Remove...661
      Disassemble and Assemble...661
      Clean and Inspect...661
        Housings...661
        Oil Seals and Gaskets...663
      Install...663
      Limp Home Function...663
    Stall Test...664
    Transmission Oil Pressure Check...665
      Pressure and Temperature Specifications...665
    Electrical Wiring and Specifications...667
      Electrical Wiring...667
      Electrical Specifications...667
    Hydraulic Cooler and Filter Lines Specifications...668
    Torque Specifications...668
      Torque Specifications for Lubricated or Plated Screw Threads...668
    Troubleshooting...670
  tables...498
    Table 1. Solenoid Controls...506
    Table 2. APC 100 Control Module (Pin Connections)...533
    Table 3. Example Torque Values at Dimensions Shown...659
    Table 4. Speed and Energized Wires...668
    Table 5. Wire Numbers and Color Codes...668
    Table 6. Grade 5...668
    Table 7. Grade 8...669
    Table 8. Grades 8.8, 10.9, and 12.9...669
    Table 9. Elastic Stop Nut Torque...670
    Table 10. O-ring Port Plug Torque Chart...670
    Table 11. Pipe Plug Torque Chart...670
1567897-8000SRM1153-(09-2005)-US-EN...674
  toc...674
    Diagrams...674
    Safety Precautions Maintenance and Repair...675
1568204-0700SRM1159-(07-2007)-US-EN...710
  toc...710
    Multiple Aligned Cooling System...710
    Safety Precautions Maintenance and Repair...711
    General...714
    Description...716
      Radiator...716
      Radiator Cap...716
      Thermostat...716
      Water Pump...717
      Fan and Fan Shroud...717
    Cooling System Checks...717
      Radiator...717
      Thermostat...717
      Water Pump...718
      Exhaust Leaks...718
      Fan and Fan Shroud...718
    Cooling System Repair...718
      Remove...718
      Install...719
    Core Repair...720
      Remove...720
      Install...720
    Radiator Cleaning...721
      Drain...721
      Clean...721
      Fill...721
    Troubleshooting...722
1569718-4000SRM1160-(01-2007)-US-EN...726
  toc...726
    Mast...726
    Safety Precautions Maintenance and Repair...727
    General...730
    Description and Operation...730
      General...730
      Lifting...731
      Lowering...731
    Safety Procedures When Working Near Mast...731
    Forks Repair...732
      Adjust...732
      Remove...732
      Install...732
        Low-Mount Fork...732
    Carriage Repair...733
      General...733
      Remove...733
      Disassemble...736
      Clean and Inspect...738
      Assemble...738
      Install...740
      Carriage Side Blocks...740
        Adjust...740
    Mast Repair...741
      Remove...741
      Disassemble...742
      Clean and Inspect...744
      Assemble...745
      Install...747
    Lift Cylinders Repair...747
      Remove...747
      Disassemble...747
      Clean and Inspect...748
      Assemble...748
      Install...748
    Fork Positioner Cylinders Repair...749
      Remove...749
      Disassemble...749
      Clean and Inspect...749
      Assemble...749
      Install...749
    Sideshift Cylinder Repair...750
      Remove...750
      Disassemble...750
      Clean and Inspect...750
      Assemble...750
      Install...750
    Header Hoses Replacement...750
    Carriage Side Blocks Adjustment...752
    Mast Side Blocks Adjustment...752
    Mast Load Rollers Adjustment...752
    Lift Chains Adjustment...753
    Lift and Tilt Cylinders Leak Check...753
    Troubleshooting...754
1572882-8000SRM1173-(12-2005)-US-EN...758
  toc...758
    Assembly Guide...758
    Safety Precautions Maintenance and Repair...759
    List of All Special Tools and Equipment Needed for the Assembly...762
    General Considerations Before Starting the Job...762
    Preparation of the Components Before Assembly...763
    Checking of the Wheels...763
      Air Pressure...763
        Drive Wheels...764
        Steer Wheels...769
      Wheel Nut Torque...773
    Installation of the Cab...775
    Preparation Of The Mast...778
      Mast...778
      Mast Label Placement...779
    Safety Procedures When Working Near Mast...780
    Mast Installation...781
      Mast...781
      Tilt Cylinder Pin Installation...783
      Truck Header Hoses and Electrical Cable Connections...785
    Installation of the Dedicated Carriage/Gantry...787
      Install...787
      Carriage Side Blocks...787
        Adjust...787
    Connection of the Hoses and Cables to the Carriages...788
    Installation of the Container Attachment on the Dedicated Carria...793
    Installation of the Container Attachment on the Gantry...795
    Lights Installation - Operator Compartment...797
    General Procedures After Assembly...798
    Hydraulic Oil Check...798
    Lubrication Points...799
    Check Points...799
      Checkpoint 1...799
      Checkpoint 2...799
      Checkpoint 3...799
      Checkpoint 4...799
      Checkpoint 5...799
    General Truck Install Procedures...799
  tables...758
    Table 1. Wire Connections...793
1573930-0600SRM1172-(03-2005)-US-EN...804
  toc...804
    Cummins Diesel Engine Fault Code Guide...804
    Safety Precautions Maintenance and Repair...805
    General...808
    Description...808
      Base Control System...808
      Fault Code Snapshot Data...808
    Maintenance Monitor (A222 Only)...809
      General...809
    Electronic Throttle Calibration...809
      Electronic Throttle Calibration Procedure...809
    Fault Codes...809
      General...809
      E117...810
        Access...810
        Exit...811
      A222...811
        Access...811
        Exit...811
  tables...804
    Table 1. Error Code Descriptions...812
1574068-1400SRM1171-(02-2008)-US-EN...826
  toc...826
    Planetary Gear Axle...826
    Safety Precautions Maintenance and Repair...827
    General...830
    Description...830
    Operation...830
    Planetary Gear Axle Repair...834
      Remove...834
        Drive Wheels and Tires...834
      Disassemble...835
        Drive Axle...835
        Planetary Gear Carrier...836
        Ring Gear, Ring Gear Hub, and Wheel Hub...837
        Hub Oil Seal and Bearings...839
        Axle Shaft...839
        Spindle...839
      Repair...840
        Repairing or Replacing Parts...840
        Welding...840
      Clean...841
        Ground or Polished Parts...841
        Parts With Rough Finishes...841
        Axle Assemblies...841
        Drying Cleaned Parts...841
      Preventing Corrosion...841
      Parts Inspection...841
      Assemble...842
        Spindle...842
        Axle Shaft...842
        Hub Oil Seal and Bearings...842
        Ring Gear, Ring Gear Hub, and Wheel Hub...843
        Wheel Bearing Preload...843
          Adjust...843
        Planetary Gear Carrier...844
        Drive Axle...845
        Wheel Ends...846
          Fill...846
      Install...846
        Drive Wheels and Tires...846
    Torque Specifications...850
    Troubleshooting...851
  tables...826
    Table 1. Wheel Bearing Adjustment Torque...843
    Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi...845
    Table 3. Standard Torque Values for Axle Fasteners...850
1578950-2200SRM1119-(08-2004)-US-EN...854
  toc...854
    Electrical System...854
    Safety Precautions Maintenance and Repair...855
    General...858
    Description...858
    Warning Devices...860
      General...860
      Description...860
        Operator-Controlled Horns...860
        Reverse Warning Horns/Lights...861
        Warning Lights...861
          Beacon Lights...861
          Brake Lights...863
          Hazard Lights...863
        Replace...863
          General...863
          Horns...863
          Horn Relay...863
          Warning Lights/Bulbs...863
          Light Assemblies...864
          Flashing Unit...864
    Meters, Senders, System Warning Lights, and Switches...864
      General...864
    Alternator...865
      General...865
      Description...865
        Charging System Indicator and Accessory Power Supply...865
      Remove...866
      Install...866
    Troubleshooting...867
897948-1300SRM0634-(03-2005)-US-EN...874
  toc...874
    Four-Speed Powershift Transmission...874
    Safety Precautions Maintenance and Repair...875
    General...878
    Automatic Powershift Control...879
      Transmission Control System...879
      Transmission Control Lever...879
    Mechanical Description and Operation...881
      General...881
      Torque Converter...881
        Description...881
        Operation...881
      Clutch Assemblies...882
        Description...882
        Operation...882
      Transmission Operation in Neutral...884
      Input Shaft, Forward Shaft, and Clutch Assembly...886
        Description...886
        Operation...886
      Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli...890
        Description...890
        Operation...890
      Third-Speed Shaft, Gear, and Clutch Assembly...890
        Description...890
        Operation...890
      Fourth-Speed Shaft and Clutch...891
        Description...891
        Operation...891
      Output Shaft...891
        Description...891
        Operation...891
    Hydraulic Description and Operation...891
      Sump, Filter, and Pump...891
      Transmission Charge Pump...893
        Pressure Regulator Valve...893
        Relief Valve...893
      Transmission Control Valve...893
        Solenoid Valves...893
        Direction Spools...894
        Range Spools...894
        Modulator Valves...894
  tables...874
    Table 1. Solenoid Controls...884
897949-1300SRM0635-(06-2007)-US-EN...900
  toc...900
    Four-Speed Powershift Transmission...900
    Safety Precautions Maintenance and Repair...901
    General...904
    Torque Converter Repair...905
      Torque Converter, Remove...905
      Torque Converter, Disassemble...905
      Clean and Inspect...907
      Torque Converter, Assemble...907
      Torque Converter (Turbine) Housing, Disassemble...908
      Relief Valve for Lube Pressure, Disassemble and Assemble...908
      Oil Sealing Rings Sleeve, Replace...908
      Torque Converter Housing, Assemble...908
      Torque Converter, Install...909
    Transmission Repair...909
      Remove, Transmission Only...909
      Transmission and Engine Assembly, Remove...910
      Transmission, Disassemble...911
        Output Shaft, Disassemble and Assemble...912
        Fourth-Speed Shaft, Disassemble and Assemble...914
        Third-Speed Shaft, Disassemble and Assemble...915
        Forward Shaft and Clutch, Disassemble and Assemble...918
        Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem...920
        First-Speed Shaft and Clutch, Disassemble and Assemble...922
        Input Shaft, Disassemble and Assemble...924
      Speed Sensor, Install...925
      Transmission, Clean and Inspect...926
      Transmission, Assemble...926
      Control Valve...928
        Clean and Inspect...928
        Assemble and Install...928
      Install, Transmission...929
      Install, Transmission and Engine Assembly...929
      Clean Oil System of Transmission After Major Repair...930
    Automatic Powershift Control (APC 100)...930
      Functional Description...930
      Fuses...933
      Transmission Control Lever...933
    First-Speed Shaft Bearings Adjustment...936
    Torque Converter Stall Speed Check...939
    Transmission Oil Pressures Check...939
      Clutch Pressures Check...939
      Torque Converter (Torque Converter Regulator) Oil Pressure Check...939
    Troubleshooting...941
      Transmission Controller (APC 100)...943
  tables...900
    Table 1. Flange Nut Torque...926
    Table 2. APC 100 Control Module (Pin Connections)...932
    Table 3. Hobbs Gear Selector Connections...935
    Table 4. Example Torque Values at Dimensions Shown...936
    Table 5. Transmission Pressures...940
910072-1400SRM0046-(07-2007)-US-EN...950
  toc...950
    Differential...950
    Safety Precautions Maintenance and Repair...951
    General...954
    Description...954
    Differential Repair...955
      Remove...955
        Differential Carrier From Axle Housing, Remove...955
        Differential and Ring Gear From Differential Carrier, Remove...957
        Drive Pinion and Pinion Carrier From Differential Carrier, Remov...959
      Disassemble...960
        Differential and Ring Gear Assembly, Disassemble...960
        Drive Pinion and Pinion Carrier, Disassemble...962
      Clean and Inspect...965
      Assemble...966
        Pinion, Bearings, and Pinion Carrier, Assemble...966
        Pinion Bearings, Adjust Preload...966
          Press Method...966
          Yoke or Flange Method...967
        Triple-Lip Seal, Install...968
        Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...969
        Differential and Ring Gear, Assemble...971
        Differential Gears Rotating Torque, Check...973
        Differential and Ring Gear Assembly, Install...974
        Differential Bearings, Preload Adjust...976
        Ring Gear, Runout Check...977
        Ring Gear Backlash, Adjust...977
        Gear Set, Tooth Contact Pattern Check...979
        Thrust Screw, Install and Adjust...982
      Install...982
        Differential Assembly Into Axle Housing, Install...982
    Specifications...984
    Troubleshooting...989
  tables...950
    Table 1. Ring Gear Backlash Adjustment Specifications...979
    Table 2. Ring and Pinion Tooth Contact Adjustment...980
    Table 3. General Specifications...984
    Table 4. Rivet Installation Pressure...984
    Table 5. Pinion Adjustment...985
    Table 6. Pinion Preload Pressure...985
    Table 7. Torque Specifications...986
    Table 8. Torque Specifications for Metric Hardware...987
    Table 9. Torque Specifications for Metric (Fine) Hardware...988
910091-1900SRM0097-(07-2006)-US-EN...992
  toc...992
    Hydraulic Gear Pumps...992
    Safety Precautions Maintenance and Repair...993
    Description...996
    Operation...997
      Flow Control Valve...997
      Relief Valve...998
    Hydraulic Gear Pump Repair...998
      Remove...998
      Disassemble...999
      Clean...999
      Inspect...1000
      Assemble...1003
      Install...1005
    Pump Output Check...1005
      Method No. 1...1005
      Method No. 2...1006
    Hydraulic System Air Check...1007
    Troubleshooting...1008
910442-8000SRM0231-(12-2004)-US-EN...1014
  toc...1014
    Metric and Inch (SAE) Fasteners...1014
    Safety Precautions Maintenance and Repair...1015
    General...1018
      Threaded Fasteners...1018
      Nomenclature, Threads...1018
      Strength Identification...1019
      Cotter (Split) Pins...1019
      Fastener Torque Tables...1024
      Conversion Table...1026
  tables...1014
    Table 1. Bolts and Screws...1020
    Table 2. Studs and Nuts...1021
    Table 3. Torque Nuts...1022
    Table 4. Torque Nuts With Nylon Insert...1023
    Table 5. Torque Values for Metric Fasteners*...1024
    Table 6. Torque Values for Inch Fasteners*...1025
    Table 7. Conversion Table for Metric and English Units...1026
    Table 8. Cotter Pin Dimensional Data...1027
    Table 9. Cotter Pin Dimensional Data...1028
    Table 10. Cotter Pin Dimensional Data...1029
    Table 11. Cotter Pin Dimensional Data...1031
Aurora_AC...1036
  912-100-0148_engl_1.pdf...0
    Compressors - Applications, Conditions of Use and Liability...1037
      ...0
        Filling procedure for refrigerants...0
          Do not exceed the maximum operating pressure of the compressor. (see type label)...1043
          Compressors are machines under pressure and as such require special care in handling...1043
          Only qualified personnel are allowed to perform any work on refrigeration compressors...1043
          The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...1043
          Never put the safety switch out of action...1043
          Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor...1043
          Prior to starting the compressor open discharge shut-off valve and suction shut-off valve...1043
          Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged...1043
          Caution! Danger of burning because of high surface temperatures...1043
          Never grab rotating parts during operation. Danger of injury!...1043
          Avoid all contact with the liquid refrigerant. Any parts of skin that come into contact with it must be treated like chilblains. Wear goggles to protect eyes. If refrigerant nevertheless gets into the eyes, consult a doctor immediately. Wear leather glov...1043
          Before repairing refrigerant circuits, all refrigerant must be suctioned off as instructed. Note: Even when the unit is empty, there may be some residual pressure. It is advisable to loosen the screws slowly to allow residual pressure to subside. Refri...1043
          No welding may be performed on any part of the unit or in the near vicinity while it is closed. Regardless whether the unit is filled with refrigerant or empty, heating causes excess pressure which can damage the unit or cause an explosion...1043
          Full bottles of refrigerant must not be thrown or...1043
          It is essential to ensure that the refrigerant system is does not become contaminated with chlorine, substances containing chlorine, oil or grease. Evacuation and filling units must be used for R 134a only...1043
    4. Troubleshooting...1044
          Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit...1044
          By wrong refrigerant level there is a danger of compressor malfunction...1044
          The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate...1044
          With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...1044
          Faulty shaft seals:On older compressors the shaft seal can be damaged when the unit is switched on for first time after a prolonged period of disuse, e.g. if the air-conditioner has not been used during the winter. Seals may become brittle as a result o...1044
          NoisesMechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operation. The normal noise made by the seals during operation does not indicate a fault. The most common noises are caused by problems with...1044
          Electrical faultsA 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by applying the required voltage to the connection socket while the vehicle engine is running. The coupling should start up with a click...1044
  912-100-0007_e.pdf...0
    Technical modifications reserved...1045
  912-100-0258_e.pdf...0
    Condenser unit, 24V...1056
      - we reserve the right to make technical modifications -...1056
    1Safety advices...1057
      Maintenance work on the refrigeration circuit:...1057
        ...1058
          2.2Condenser blowers...1058
          5Electrical connection...1059
      every six months – authorised workshop:...1060
              State of the refrigerant hoses...1060
        State of the condenser...1060
      A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)...1060
      every month sight checks - Operator...1061
              State of the refrigerant hoses...1061
        State of the condenser...1061
      Check condenser of contamination by dust, insects or parts of plants...1061
      A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)...1061
        Installation of replacement parts...1061
          8Technical data...1061
          9Fault diagnosis...1062

Hyster Forklift Trucks E117 (H1050HD-CH, H1150HD-CH) Repair Service Manuals