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
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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