Complete service repair manual for Hyster Lift Trucks H800-970E, H1050EH (D117), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster Service Manual H800E-H970E, H1050EH (D117) 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.
1453783 – Hyster Service Manual H800-970E, H1050EH (D117) .pdf
Total Pages: 883 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section | Part No. | SRM Number | Rev Date |
| FRAME | 1454304 | 0100 SRM 0692 | 12/02 |
| COOLING SYSTEM | 897934 | 0700 SRM 0626 | 11/01 |
| FOUR-SPEED PS TRANSMISSION – DESCR / OPER | 897948 | 1300 SRM 0634 | 11/03 |
| FOUR-SPEED PS TRANSMISSION – REPAIR | 897949 | 1300 SRM 0635 | 11/03 |
| DIFFERENTIAL | 910072 | 1400 SRM 0046 | 11/03 |
| PLANETARY GEAR AXLE | 910030 | 1400 SRM 0047 | 11/03 |
| STEERING AXLE | 910031 | 1600 SRM 0071 | 07/97 |
| STEERING SYSTEM | 897367 | 1600 SRM 0429 | 04/97 |
| OIL COOLED BRAKES | 1452928 | 1800 SRM 0678 | 09/03 |
| DISC BRAKES | 1453346 | 1800 SRM 0683 | 08/02 |
| ACCUMULATOR | 1529749 | 1800 SRM 1036 | 09/02 |
| PARKING BRAKE | 1531821 | 1800 SRM 1037 | 02/03 |
| SERVICE BRAKES (Later Units) | 1531822 | 1800 SRM 1038 | 11/03 |
| AUXILARY BRAKE CALIPER | 1531815 | 1800 SRM 1040 | 04/03 |
| HYDRAULIC GEAR PUMPS | 910091 | 1900 SRM 0097 | 10/03 |
| HYDRAULIC SYSTEM | 1452932 | 1900 SRM 0682 | 07/97 |
| HYDRAULIC PLATE (See SRM for S/N break) | 1513622 | 1900 SRM 1012 | 09/03 |
| HYDRAULIC SYSTEM (See SRM for S/N break) | 1514035 | 1900 SRM 1013 | 12/02 |
| TILT CYLINDERS | 910102 | 2100 SRM 0103 | 10/03 |
| INSTRUMENT PANEL INDICATORS and SENDERS | 910110 | 2200 SRM 0143 | 12/03 |
| ELECTRICAL SYSTEM | 1452929 | 2200 SRM 0679 | 11/03 |
| MAST | 897371 | 4000 SRM 0432 | 03/97 |
| EXTENDABLE CONTAINER ATTACHMENT | 910457 | 5000 SRM 0265 | 11/97 |
| FIXED CONTAINER ATTACHMENT | 910466 | 5000 SRM 0266 | 11/97 |
| EXTENDABLE CONTAINER ATTACHMENT (ELME) | 1462736 | 5000 SRM 0723 | 11/99 |
| INCH (SAE) and METRIC FASTENERS | 910442 | 8000 SRM 0231 | 03/03 |
| DIAGRAMS | 1452553 | 8000 SRM 0676 | 08/02 |
| PERIODIC MAINTENANCE | 1452927 | 8000 SRM 0677 | 10/03 |
| CAPACITIES and SPECIFICATIONS | 1452930 | 8000 SRM 0680 | 12/02 |
| ASSEMBLY GUIDE | 1526432 | 8000 SRM 1041 | 07/02 |
| For service and repair information on Cummins engines | |||
| see a dealer for Cummins engines. | |||
| PART NO. 1453783 | |||
| Rev. 12/03 | |||
Diagrams…2
Safety Precautions Maintenance and Repair…3
hyster-1452927-10-03-srm0677…26
toc…26
Periodic Maintenance…26
Safety Precautions Maintenance and Repair…27
General…32
Serial Number Data…32
How to Move Disabled Lift Truck…32
How to Tow Lift Truck…33
How to Put Lift Truck on Blocks…33
How to Raise Drive Tires…33
How to Raise Steering Tires…34
Maintenance Schedule…35
Maintenance Procedures Every 8 Hours or Daily…48
How to Make Checks With Engine Stopped…48
Tires and Wheels…48
Forks…48
Adjust…49
Remove…49
Low Mount Forks, Install…49
High Mount Forks, Install…49
Inspection of Forks, Mast, and Lift Chains…49
Precleaner for Air Filter…50
Air Filter…50
Safety Labels…51
Operator Restraint System…52
Steering Column Latch…52
Fuel, Oil, or Coolant Leak Check…52
Drive Belt…52
Engine Oil…52
Cooling System…54
Hydraulic System Oil…54
Hydraulic Oil Filters…55
Hydraulic Filter…55
Battery…56
Splash Fuses…56
How to Make Checks With Engine Running…57
Engine Fault Codes…57
Gauges, Lights, Horn, Fuses, and Relays…63
Engine Oil Pressure…63
Electrical System…63
Transmission Oil…63
Steering System…64
Service Brakes…64
Parking Brake…64
Fuel System…64
Primary Fuel Filter…64
Control Levers and Pedals…64
Lift System Operation…65
Attachments…65
How to Add Fuel to Lift Truck…65
Maintenance Procedures Every 250 Hours or Each Month…66
Engine Oil and Filter…66
Oil Filter for Oil Cooled Brakes…66
Transmission…66
Coolant Filter…66
Lift Chains…67
Drive Shaft…67
Steering Axle Tie Rod Pins…67
Drive Axle and Differential…67
Heater Air Filter…67
Wheel Nuts…67
Mast Pivots, Sliding Surfaces…67
Sideshift Carriage…67
Fork Guides…67
Tilt Cylinder Pins…67
Shift Control Lever…67
Dedicated Carriage and Container Attachments…68
Maintenance Procedures Every 500 Hours or 2 Months…68
Forks…68
Lift Chains…68
Idle Speed…69
Governed Speed…69
Hydraulic Tank Breather…69
Maintenance Procedures Every 1000 Hours or 6 Months…69
Steer Wheel Bearing Nut…69
Change Transmission Oil…70
Fuel Filter…70
Chain Sheaves…70
Mast and Carriage Load Rollers…70
General Lubrication…70
Injection Pump Timing…70
Valve Adjustments…70
Steering Axle Kingpins…70
Disc Brake Assemblies…71
Clean…71
Inspect…71
Maintenance Procedures Every 2000 Hours or Yearly…73
Change Hydraulic Oil and Filters…73
Cooling System…73
Change Drive Axle and Differential Oil…74
Change Grease in Hub Bearings of Steer Wheels…74
Steering Axle Pivots…74
PCV Valve…74
Safety Procedures When Working Near Mast…74
Lift and Tilt System Leaks Check…76
Lift System…76
Tilt System…76
Pneumatic Tires and Wheels…77
Remove Wheels From Lift Truck…77
Remove Tire From Wheel…77
Remove Tire From Five-Piece Wheel…78
Install Tire on Wheel…79
Install Tire on Five-Piece Wheel…80
Add Air Pressure to Tires…81
Install Wheels on Lift Truck…82
tables…26
Table 1. Maintenance Schedule…35
Table 2. Maintenance Schedule, Container Attachment Until Mid 19…43
Table 3. Maintenance Schedule, Dedicated Container Attachment Af…44
Table 4. Maintenance Schedule, Fork Mounted Container Attachment…45
Table 5. Maintenance Schedule, Gantry Container Attachment After…46
Table 6. Error Code Descriptions…57
Table 7. Steer Wheel Nut Torque Specifications…69
hyster-1452928-09-03-srm0678…86
toc…86
Oil-Cooled Brakes…86
Safety Precautions Maintenance and Repair…87
General…90
Description…90
D117…91
E008…91
Description and Operation…94
D117…94
E008…94
Accumulator Charge Valve…95
Pressure Reducing Valves…97
Brake Pedal Valves…98
Operation…98
Operation (D117 E 01550, and After) (E008 Wet Brakes)…98
Parking Brake…99
Service Brakes…99
Auxiliary Brake (D117 only)…99
Pressure Switch Replacement…100
Accumulator Charge Valve Repair…100
Remove…100
Disassemble…100
Clean and Inspect…102
Assemble…102
Install…103
Adjust…103
Accumulator…103
Relay Valve Repair…103
Remove…103
Disassemble…104
Clean and Inspect…104
Assemble…104
Install…104
Shuttle Valve Repair…105
Remove…105
Disassemble…105
Clean and Inspect…105
Assemble…105
Install…105
Brake Pedal Valves (Treadle Valves) Repair…106
Remove…106
Clean and Inspect…106
Install…106
Inching Valve Repair…110
Remove…110
Disassemble…110
Clean and Inspect…110
Assemble…110
Install…112
Brake System Air Removal…112
Troubleshooting…113
tables…86
Table 1. Accumulator Charge Valve Pressures…95
Table 2. Brake Treadle Settings…98
hyster-1452929-11-03-srm0679…130
toc…130
Electrical System/Lights…130
Safety Precautions Maintenance and Repair…131
General…134
Alternator…134
Description…134
Remove and Disassemble…135
Clean…135
Inspect, Test, and Repair…135
Rotor…135
Rectifiers and Diode Set…136
To Test Rectifier With Ohmmeter:…136
To Test Rectifier With Test Lamp:…137
To Test Diode Set:…137
Drive End Frame…137
Brush End Frame…137
Brushes and Brush Holder Assembly…137
Stator…137
Assemble and Install…137
Meters, Senders, and Switches…138
General…138
Troubleshooting…138
hyster-1452930-12-02-srm0680…150
toc…150
Capacities and Specifications…150
Safety Precautions Maintenance and Repair…151
Counterweights Weights…154
Container Attachment Weights…154
Carriage Weights…154
Vehicle Weights…154
Capacities…155
Electrical System…155
Engine Specifications…155
Mast Weights…156
Lifting and Lowering Speeds…156
Tires…157
Forks…157
Hydraulic System Specifications…157
Torque Specifications…159
Control Valves…159
Electrical System…159
Counterweight…159
Drive Axle…159
Disc Brakes…159
Drive Shaft…159
Differential…159
Transmission…159
Torque Converter…160
Steering…160
Wheel Nuts…160
Carriages (All)…160
Disc Brakes…212
Safety Precautions Maintenance and Repair…213
General…216
Description and Operation…216
Accumulator Charge Valve…218
Pressure Reducing Valves…220
Brake Pedal Valves…220
Operation…220
Parking Brake…221
Service Brakes…221
Auxiliary Brake…222
Pressure Switch Replacement…222
Accumulator Charge Valve Repair…222
Remove…222
Disassemble…222
Clean and Inspect…224
Assemble…224
Install…225
Adjust…225
Accumulator…225
Pressure Reducing Valves Repair…225
Remove and Disassemble…225
Clean and Inspect…225
Assemble and Install…226
Relay Valve Repair…227
Remove and Disassemble…227
Clean and Inspect…227
Assemble…227
Install…228
Shuttle and Sequence Valves Repair…228
Remove and Disassemble…228
Clean and Inspect…228
Assemble and Install…228
Brake Pedal Valves (Treadle Valves) Repair…229
Remove and Disassemble…229
Clean and Inspect…229
Assemble and Install…229
Inching Valve Repair…233
Remove…233
Disassemble…233
Clean and Inspect…233
Assemble…233
Install…233
Service Brake Calipers Repair…235
Remove…235
Disassemble…235
Clean…237
Inspect…237
Assemble…238
Install…239
Brake System Air Removal…240
Troubleshooting…241
hyster-1454304-12-02-srm0692…252
toc…252
Frame…252
Safety Precautions Maintenance and Repair…253
General…256
Description…256
Counterweight Repair…257
Remove…257
Install…257
Fenders Repair…258
Remove…258
Install…258
Hood and Ballast Cover…258
Hood…258
Remove…258
Install…258
Ballast…258
Remove…258
Install…258
Floor Plates and Covers…262
Hydraulic Tank Repair…263
Remove…263
Repair…263
Small Leaks…263
Large Leaks…263
Clean…263
Steam Method…265
Chemical Solution Method…265
Other Methods of Preparation for Repair…265
Install…265
Fuel Tank Repair…266
Remove…266
Repair…266
Install…266
Radiator Repair…267
Remove…267
Clean…268
Install…269
Engine Repair…270
Remove…270
Install…273
Operator Compartment Repair…274
General…274
Remove…279
Install…280
Gauges and Switches Repair…280
Window Wipers Repair…281
Single Arm Wipers…281
Double Arm Wipers…281
Window Washer Motor/Pumps…281
Fuse Panel…282
Heater Assembly Repair…283
Remove…283
Heater Control Panel Assembly…283
Blower and Core Assemblies…283
Install…283
Door Handle Assembly…286
Door Retainer Assemblies…286
Window Replacement…287
Front and Rear Windows…287
Lower Door Windows…288
Upper Door (Slider) Windows…288
Top Window…288
Operator Restraint System Repair…289
Label Replacement…289
Description and Operation…323
Hydraulic Oil Supply…323
D117…323
E008…323
Manifold, Section 1 of Hydraulic Plate…323
Two-Spool and Single-Spool Main Control Valves, Section 2 and 3 …325
Flow Amplifier, Section 4 of Hydraulic Plate…325
Return Manifold, Section 5 of Hydraulic Plate…325
Hydraulic Filter…329
Relay Valve (D117 Only)…329
Manual Override (E008 Only)…329
Main Manifold Repair…330
General…330
Valves and Pressure Switches…331
Main Control Valves Repair…333
Single Spool and Two Spool…333
Flow Amplifier Repair…333
Hydraulic Hose Repair…333
Torque Values…333
Measurements and Adjustments…334
Measurements…334
Adjustments…334
Table 1. Accumulator Charge Valve Pressures…324
Table 2. Brake Treadle Settings…324
Table 3. Pressure Settings…335
Hydraulic System…348
Safety Precautions Maintenance and Repair…349
General…354
Description and Operation…354
Hydraulic Plate…354
Main Control Valves…355
Remote Control Valve…355
Lift Manifold…355
Accumulator Charge Valve…356
Directional Control Valve…356
Carriage Solenoid Valves…356
Heat Exchanger System…356
Steering Control System…356
Brake System…357
Lift and Lower Circuit…357
Description…357
Operation…357
Lift Circuit, Normal Speed (Heavy Load)…360
Lift Circuit, High Speed (Light Load)…360
Lowering…360
Lowering Control Valves…360
Repairs…361
General…361
Hydraulic Plate, Remove…361
Remote Control Valve…361
Remove…361
Disassemble…362
Clean and Inspect…363
Assemble…363
Install…363
Main Control Valves…363
Remove…363
Disassemble…363
Clean and Inspect…365
Assemble…365
Install…365
Lift Manifold…365
Remove…365
Clean and Inspect…366
Assemble and Install…366
Checks and Adjustments…367
Pilot Relief Pressure, Check…367
Main Control Valves Relief Pressure, Check…367
Lift Manifold, Check…368
Remote Control Valve, Adjust…368
Tilt Control Circuit…368
Description…368
Operation…369
Tilt Spool…369
Relief Valves in Main Control Valve…369
Relief Valves, Tilt Lock…371
Repairs…371
General…371
Main Control Valve (Two-Spool), Replace…371
Relief Valves, Tilt Lock, Disassemble…372
Clean and Inspect…372
Checks and Adjustments…372
Main Control Valve Relief Pressure, Check…372
Attachment Circuit Valves…373
General…373
Directional Control Valve…373
Carriage Solenoid Valve…373
Repairs…373
Directional Control Valve…373
Remove…373
Disassemble…374
Clean and Inspect…376
Assemble…376
Install…376
Return Control Valves…376
Carriage Solenoid Valve…377
Remove…377
Disassemble…378
Clean and Inspect…378
Assemble…378
Install…378
Checks and Adjustments…378
Other Hydraulic Components…379
Description and Operation…379
Accumulator Charge Valves…379
Relief Valve in Accumulator Charge Circuit…379
Relief Valves in Steering and Lift Circuits…379
Reducer Valve…379
Over Lowering Interrupt…379
Lift Interrupt…379
Hydraulic Filter…380
Checks and Adjustments…380
Relief Valves, Check and Adjust…380
Pilot Pressure, Check…381
Torque Specifications…381
Main Control Valves…381
Remote Control Valves…381
Attachment Control Valve…381
Carriage Solenoid Valve…381
Specifications…381
Hydraulic Pumps Output at 2286 rpm (Governed Speed – No Load)…381
Relief Valves (Approximate Operating Pressures)…382
Check Port Pressures…382
Main Hydraulic Filters…382
Tank Capacity…382
Troubleshooting…383
Lift and Lower Circuit…383
Tilt Circuit…385
Attachment Circuit Valves…387
Attachment Control Valve…388
Carriage Solenoid Valve…389
Other Hydraulic Components…389
Accumulator Circuit…389
2.1 MPa ( 300 psi) Pilot Circuit…390
Park Brake Circuit…390
tables…348
Table 1. Accumulator Charge Valve Pressures…356
Table 2. Brake Treadle Settings…357
hyster-1526432-07-02-srm1041…400
toc…400
Assembly Guide…400
Safety Precautions Maintenance and Repair…401
List of All Special Tools and Equipment Needed for the Assembly…404
General Considerations Before Starting the Job…404
Preparation of the Components Before Assembly…405
Installation and Checking of the Wheels…406
Installation of the Cab…411
Installation of the Mast…411
Installation of Carriage Equipped With Forks…419
Installation of the Dedicated Carriage…419
Installation of the Gantry…420
Connection of the Hoses and Cables to the Carriages…421
Harness Installation Instructions…423
Installation of the Forks…425
Low-Mounted Forks…425
Installation of the Low-Mount Quick-Disconnect Type Forks…425
Installation of the Low-Mount Pin-Mounted Forks…427
High-Mounted Forks…428
Installation of the High-Mount Quick-Disconnect Forks…428
Installation of the High-Mount Pin-Mounted Forks…429
Installation of the Container Attachment on Forks…430
Installation of the Container Attachment on the Dedicated Carria…432
Installation of the Container Attachment on the Gantry…433
Lights Installation…434
General Procedures After Assembly…435
Accumulator…438
Safety Precautions Maintenance and Repair…439
General…442
Description and Operation…442
Accumulator Maintenance…442
Precharge Check…442
Precharge Filling…442
Remove…443
Disassemble…444
Clean…445
Inspect…445
Repair…445
Assemble…445
Replace…445
Auxiliary Brake Caliper…448
Safety Precautions Maintenance and Repair…449
General…452
Description and Operation…452
Auxiliary Brake Caliper Repair…453
Brake Linings…453
Remove…453
Clean and Inspect…453
Install…454
Auxiliary Caliper…454
Remove…454
Disassemble…455
Caliper…455
Piston Subassembly…456
Clean…457
Inspect…458
Caliper…458
Rotor…458
Piston Return Spring…458
Piston Assembly Return Spring Force and Built-In Clearance…459
Piston Assembly Adjuster Grip Force…460
Grip Force Adjuster Grip Assembly…462
Assemble…463
Piston Subassembly…463
Caliper…464
Install…464
Bleed Brakes…465
Adjust…465
Troubleshooting…466
tables…448
Table 1. Rotor Wear Limits…458
Parking Brake…470
Safety Precautions Maintenance and Repair…471
General…474
Description and Operation…474
Parking Brake Caliper Repair…475
Release Brake Manually…475
Hydraulic Pressure Available…475
Hydraulic Pressure not Available…475
Remove…475
Disassemble…476
Clean…478
Inspect…478
Linings…478
Disc…478
Caliper Parts…479
Assemble…479
Install…481
Bleed Brakes…481
Adjust…482
Test…482
Specifications…483
Troubleshooting…483
tables…470
Table 1. Disc Wear Limits…479
Table 2. Torque Requirements…483
Table 3. Wear Limits…483
Table 4. Lining to Disc Clearance…483
hyster-1531822-11-03-srm1038…488
toc…488
Service Brake…488
Safety Precautions Maintenance and Repair…489
General…492
Description and Operation…492
Repair…493
Remove…493
Brake Assembly…493
Spindle and Brake Cover…496
Disassemble…497
Clean…499
Ground and Polished Parts…499
Parts With Rough Finish…499
Wet Disc Brake and Axle Assembly…499
Inspect…499
Face Seals…499
Disc…500
Wear Limits…500
Replace…500
Parts…500
Assemble…500
Brake Housings…500
Install…503
Hub Oil Seals…503
Double Seals…503
Single Seal…503
Spindle and Brake Cover…504
Brake Housing…506
Specifications…509
Brake Coolant…512
Coolant Change Intervals…512
Break-In…512
Normal Maintenance…512
Hydraulic Fluid…512
Troubleshooting…512
tables…488
Table 1. FRICTION DISC…500
Table 2. STATIONARY DISC…500
Table 3. Wheel Hub and Brake Housing Torque Chart…509
Table 4. Brake Housing Cover Torque Chart…511
Cooling System…574
Safety Precautions Maintenance and Repair…575
General…578
Description…579
Radiator…579
Radiator Cap…579
Thermostat…579
Water Pump…580
Fan and Fan Shroud…580
Cooling System Checks…580
Radiator…580
Thermostat…580
Water Pump…581
Exhaust Leaks…581
Fan and Fan Shroud…581
Radiator Cleaning…581
Drain…581
Clean…581
Fill…582
Troubleshooting…583
hyster-897948-11-03-srm0634…586
toc…586
Four-Speed Powershift Transmission…586
Safety Precautions Maintenance and Repair…587
General…590
Automatic Powershift Control…591
Transmission Control System…591
Transmission Control Lever…591
Mechanical Description and Operation…593
General…593
Torque Converter…593
Description…593
Operation…593
Clutch Assemblies…593
Description…593
Operation…594
Transmission Operation in Neutral…597
Input Shaft, Forward Shaft, and Clutch Assembly…597
Description…597
Operation…597
Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli…601
Description…601
Operation…601
Third-Speed Shaft, Gear, and Clutch Assembly…601
Description…601
Operation…601
Fourth-Speed Shaft and Clutch…601
Description…601
Operation…602
Output Shaft…602
Description…602
Operation…602
Hydraulic Description and Operation…602
Sump, Filter, and Pump…602
Transmission Charge Pump…602
Pressure Regulator Valve…602
Relief Valve…602
Transmission Control Valve…603
Solenoid Valves…604
Direction Spools…604
Range Spools…604
Modulator Valves…604
tables…586
Table 1. Gear, Solenoid, and Clutch Selections…594
hyster-897949-11-03-srm0635…610
toc…610
Four-Speed Powershift Transmission…610
Safety Precautions Maintenance and Repair…611
General…614
Torque Converter Repair…615
Torque Converter, Remove…615
Torque Converter, Disassemble…615
Clean and Inspect…615
Torque Converter, Assemble…615
Torque Converter (Turbine) Housing, Disassemble…618
Relief Valve for Lube Pressure, Disassemble and Assemble…618
Oil Sealing Rings Sleeve, Replace…618
Torque Converter Housing, Assemble…619
Torque Converter, Install…619
Transmission Repair…619
Remove, Transmission Only…619
Remove, Transmission and Engine Assembly…620
Transmission, Disassemble…621
Output Shaft, Disassemble and Assemble…622
Fourth-Speed Shaft, Disassemble and Assemble…623
Third-Speed Shaft, Disassemble and Assemble…624
Forward Shaft and Clutch, Disassemble and Assemble…627
Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem…629
First-Speed Shaft and Clutch, Disassemble and Assemble…631
Input Shaft, Disassemble and Assemble…633
Speed Sensor, Install…633
Transmission, Clean and Inspect…635
Transmission, Assemble…635
Control Valve…637
Clean and Inspect…637
Assemble and Install…637
Install, Transmission …638
Install, Transmission and Engine Assembly…638
Clean Oil System of Transmission after Major Repair…639
Automatic Powershift Control (APC 100)…639
Functional Description…639
Fuses…642
Transmission Control Lever…642
First-Speed Shaft Bearings Adjustment…645
Torque Converter Stall Speed Check…648
Transmission Oil Pressures Check…648
Clutch Pressures Check…648
Torque Converter (Torque Converter Regulator) Oil Pressure Check…648
Troubleshooting…650
Transmission Controller (APC 100)…651
tables…610
Table 1. Flange Nut Torque…635
Table 2. APC 100 Control Module (Pin Connections)…641
Table 3. Hobbs Gear Selector Connections…644
Table 4. Example Torque Values at Dimensions Shown…646
Table 5. Transmission Pressures…649
hyster-910030-11-03-srm0047…658
toc…658
Planetary Gear Axle…658
Safety Precautions Maintenance and Repair…659
General…662
Description…662
Operation…663
Planetary Gear Axle Repair…664
Remove…664
Disassemble…664
Planetary Axle, Disassemble…667
Assemble and Install…671
Planetary Axle, Assemble…672
Torque Specifications…677
Troubleshooting…680
tables…658
Table 1. Axle-to-Frame Fasteners…671
Table 2. Standard Torque Values for Axle Fasteners…677
Table 3. Drive Wheel Nut Torque…677
Description…704
Differential Repair…704
Remove…704
Differential Carrier From Axle Housing, Remove…704
Differential and Ring Gear From Differential Carrier, Remove…708
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…710
Disassemble…711
Differential and Ring Gear Assembly, Disassemble…711
Drive Pinion and Pinion Carrier, Disassemble…713
Clean and Inspect…715
Assemble…716
Pinion, Bearings, and Pinion Carrier, Assemble…716
Pinion Bearings, Adjust Preload…717
Press Method…717
Yoke or Flange Method…717
Triple-Lip Seal, Install…718
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…719
Differential and Ring Gear, Assemble…721
Differential Gears Rotating Torque, Check…724
Differential and Ring Gear Assembly, Install…725
Differential Bearings, Preload Adjust…726
Ring Gear, Runout Check…727
Ring Gear Backlash, Adjust…727
Gear Set, Tooth Contact Pattern Check…729
Thrust Screw, Install and Adjust…731
Install…732
Differential Assembly Into Axle Housing, Install…732
Specifications…734
Troubleshooting…738
tables…700
Table 1. Ring Gear Backlash Adjustment Specifications…728
Table 2. Ring and Pinion Tooth Contact Adjustment…730
Table 3. General Specifications…734
Table 4. Rivet Installation Pressure…734
Table 5. Pinion Adjustment…734
Table 6. Pinion Preload Pressure…735
Table 7. Torque Specifications…736
Table 8. Torque Specifications for Metric Hardware…737
Table 9. Torque Specifications for Metric (Fine) Hardware…737
hyster-910091-10-03-srm0097…742
toc…742
Hydraulic Gear Pumps…742
Safety Precautions Maintenance and Repair…743
Description…746
Operation…747
Flow Control Valve…747
Relief Valve…748
Hydraulic Gear Pump Repair…748
Remove…748
Disassemble…749
Clean…749
Inspect…750
Assemble…753
Install…755
Pump Output Check…755
Method No. 1…755
Method No. 2…756
Hydraulic System Air Check…757
Troubleshooting…758
hyster-910102-10-03-srm0103…764
toc…764
Tilt Cylinders…764
Safety Precautions Maintenance and Repair…765
General…768
Description…768
Tilt Cylinder Repair…768
Remove…768
Disassemble…768
Clean…768
Assemble…769
Tilt Cylinders With O-Ring or Single-Lip Seals…769
Tilt Cylinders for XM and XMS Models…770
Tilt Cylinders for H700-800A and Early Model H700-920B…771
Install…772
Tilt Cylinders Using Chevron Packing…773
Install…774
Tilt Cylinder Leak Check…776
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…777
Torque Specifications…778
Piston Rod Nut…778
Retainer…779
Troubleshooting…781
tables…764
Table 1. Movement Rates (Maximum) for Tilt Cylinders…777
hyster-910110-12-03-srm0143…784
toc…784
Instrument Panel Indicators and Senders…784
Safety Precautions Maintenance and Repair…785
General…788
Description…789
Steering Column Gauges, Meters, and Indicators…789
LED Display Panel…789
Battery Discharge Indicators…789
Brush Wear Indicators…796
Motor Temperature Indicators…796
LX Series Display Panel…798
Hourmeter Functions…798
Battery Indicator Function…799
Status Code Function…800
ZX Series Display Panels…800
Display Panel…800
Basic Display Panels…800
Performance Display…803
Brush Wear Indicators…806
Adjustments – General…807
Replacement – General Information…807
Meter Replacement…808
Sender Replacement…809
Fuel Level Sender…809
Pressure and Temperature Sender…809
ITW Display Panel Replacement…810
Remove…810
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…811
Remove…811
Display Panel Assembly, Replace…811
Indicator LEDs…812
Battery Indicators…812
Digital Display (Performance Display Panel Only)…812
Status Code or Performance Level Switches and Indicator LEDs (Pe…812
Basic Display Panel, Replace Parts…812
Performance Display Panel, Replace Parts…814
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…815
Remove and Replace…815
Specifications…815
Meter Specifications…815
Sender Specifications…816
Troubleshooting…816
Meter…816
hyster-910442-03-03-srm0231…820
toc…820
Metric and Inch (SAE) Fasteners…820
Safety Precautions Maintenance and Repair…821
General…824
Threaded Fasteners…824
Nomenclature, Threads…824
Strength Identification…825
Cotter (Split) Pins…825
Fastener Torque Tables…830
Conversion Table…832
tables…820
Table 1. Bolts and Screws…826
Table 2. Studs and Nuts…827
Table 3. Torque Nuts…828
Table 4. Torque Nuts With Nylon Insert…829
Table 5. Torque Values for Metric Fasteners*…830
Table 6. Torque Values for Inch Fasteners*…831
Table 7. Conversion Table for Metric and English units…832
Table 8. Cotter Pin Dimensional Data…833
Hyster H800-970E, H1050EH (D117) Repair Service Manual
