Hyster A917 (H800-900-1050HD, H800-900-970-1050HDS) Container Handler Forklift Service Manual
1,382 pages · Publication 1641090
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Added to your cart. View cart
- Models
- A917 (H800-900-1050HD, H800-900-970-1050HDS)
- Manual type
- Service Manual
- Pages
- 1,382
- Publication
- 1641090
- Condition
- Brand new
What's inside
From the manual's own table of contents: 228 sections, 504 entries. See sample pages (PDF, 212 KB)
Differential
Safety Precautions Maintenance and Repair
General
Description
Differential Repair5 topics
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
Specifications
Troubleshooting
Table 1. Ring Gear Backlash Adjustment Specifications
Table 2. Ring and Pinion Tooth Contact Adjustment
Table 3. General Specifications
Table 4. Rivet Installation Pressure
Table 5. Pinion Adjustment
Table 6. Pinion Preload Pressure
Table 7. Torque Specifications
Table 8. Torque Specifications for Metric Hardware
Table 9. Torque Specifications for Metric (Fine) Hardware
Hydraulic Gear Pumps
Operation2 topics
- Flow Control Valve
- Relief Valve
Hydraulic Gear Pump Repair2 topics
- Clean
- Inspect
Pump Output Check2 topics
- Method No. 1
- Method No. 2
Hydraulic System Air Check
Brake Accumulator
Description and Operation
Accumulator Maintenance4 topics
- Pre-Charge Check
- Pre-Charge Filling
- Repair
- Replace
Show all 228 sections
Table 1. Accumulator Pressures
Service Brake1 topic
- B222 Only
Repair3 topics
- General
- Pressure Switch
- Accumulator
Brake Pedal Valves (Treadle Valves) Repair
Brake System Air Removal2 topics
- Brake Coolant
- Hydraulic Fluid
Measurements and Adjustments
Table 1. Friction Disc
Table 2. Stationary Disc
Table 3. Wheel Hub and Brake Housing Torque Chart
Table 4. Brake Housing Cover Torque Chart
Tilt Cylinders
Tilt Cylinder Repair
Tilt Cylinder Leak Check
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment
Torque Specifications
Table 1. Movement Rate (Maximum) for Tilt Cylinders
Parking Brake
Parking Brake Valve Replacement
Parking Brake Caliper Repair2 topics
- Bleed Brakes
- Adjust
Brake Pad Repair
Seals Repair3 topics
- Torque Requirements
- Wear Limits
- Lining to Disc Clearance
Table 1. Brake Pad Adjustment
Table 2. Torque Requirements
Table 3. Wear Limits
Table 4. Lining to Disc Clearance
Mast2 topics
- Lifting
- Lowering
Safety Procedures When Working Near Mast
Forks Repair
Carriage Repair1 topic
- Carriage Side Blocks
Mast Repair
Lift Cylinders Repair
Fork Positioner Cylinders Repair
Sideshift Cylinder Repair
Header Hoses Replacement
Carriage Side Blocks Adjustment
Mast Side Blocks Adjustment
Mast Load Rollers Adjustment
Lift Chains Adjustment
Lift and Tilt Cylinders Leak Check
Planetary Gear Axle
Planetary Gear Axle Repair2 topics
- Preventing Corrosion
- Parts Inspection
Table 1. Wheel Bearing Adjustment Torque
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi
Table 3. Standard Torque Values for Axle Fasteners
Hydraulic Plate6 topics
- Hydraulic Oil Supply
- Manifold, Section 1 of Hydraulic Plate
- Main Control Valve, Section 2 of Hydraulic Plate
- Return Manifold, Section 3 of Hydraulic Plate
- Brake Manifold, Section 4 of Hydraulic Plate
- Flow Amplifier, Section 5 of Hydraulic Plate
Manifold, Section 1 of Hydraulic Plate1 topic
- Valves and Pressure Switches
Main Control Valve, Section 2 of Hydraulic Plate
Return Manifold, Section 3 of Hydraulic Plate
Brake Manifold, Section 4 of Hydraulic Plate
Flow Amplifier, Section 5 of Hydraulic Plate
Hydraulic Hose Repair
Hydraulic Hose Identification
Torque Values2 topics
- Measurements
- Adjustments
Table 1. Pilot Hoses
Table 2. Brake Hoses
Table 3. Auxiliary Hoses With Alternating P and T
Table 4. Steer Hoses
Table 5. Pressure Settings at 2100 RPM
Instrument Panel Indicators and Senders2 topics
- Instrument Panel Meters, Indicators, and LCD Display
- Connector
Instrument Panel Component Replacement2 topics
- Instrument Panel
- Light
Sender Replacement6 topics
- Fuel Level Sender
- Pressure Sender
- Temperature Sender
- Low Coolant Sender
- Vacuum Switch
- Crankshaft Position Sensor
Table 1. Instrument Panel and Indicators
Table 2. Pin Description
Table 3. Sender Description
Diagrams
Periodic Maintenance4 topics
- Serial Number Data
- How to Move Disabled Lift Truck
- How to Put Lift Truck on Blocks
- How to Clean a Lift Truck
Maintenance Schedule1 topic
- Spreader Maintenance
Maintenance Procedures Every 8 Hours or Daily2 topics
- How to Make Checks With the Engine Stopped
- How to Make Checks With Engine Running
First Inspection After First 100 Hours of Operation5 topics
- Lift Chains
- Bearing Pretorque in Steer Wheel Hubs
- Transmission Oil Filter
- Brake Return Line Filter
- High Pressure Hydraulic Filter
Maintenance Procedures Every 250 Hours or 3 Months33 topics
- Warnings and Safety Labels
- Wheels, Tires and Tire Pressure
- Mast, Carriage, Attachment
- Hydraulic Tank Breathers
- Air Precleaner
- Fuel, Oil, and Coolant Leaks
- Engine Air Intake Piping and Charge Air Piping
- Coolant Hoses
- Drive Belts
- Engine Compartment
- Radiator sections for Engine Coolant, Charge Air Cooler, Transmi
- Oil in Steer Wheel Hubs
- Drive Axle and Differential
- Windshield Washer Fluid
- Hydraulic System Oil
- Coolant Level
- Engine Oil Level
- Fuel Filter / Water Separator
- Transmission Oil Level
- Seat Belt, Seat Rails and Steering Column
- Steering Column Latch
- Operator Presence System
- Chain Sheave Bearings
- Inner Mast Rollers
- Carriage Rollers
- Mast Pivot Pins
- Tilt Cylinder Pivot Pins
- Fork Pins and Guides
- Steering Axle Tie Rod Pins
- Drive Shaft
- Attachment
- Twist Locks
- Signals from the Spreader Control System
Maintenance Procedures Every 500 Hours or 3 Months7 topics
- Steer Axle King Pin
- Steering Axle Pivot
- Attachment Bearing Pads and Bearing Pad Tracks
- Locking Plate for Stop Cylinder
- Hangers
- Slewing Cylinders
- Fork Contact Area with Spreader Pads
Maintenance Procedures Every 500 Hours or 6 Months4 topics
- Header Hose Assembly
- Cab Air Filter
- Cooling Fan
- Engine Oil and Oil Filter
Maintenance Procedures Every 1000 Hours2 topics
- Stop Cylinders
- Extension Cylinder Supports
Maintenance Procedures Every 1000 Hours or 6 Months4 topics
- Parking and Service Brakes
- Coolant Quality
- Operator's Cab Door Hinges
- Transmission Oil and Oil Filter
Maintenance Procedures Every 1500 Hours or 6 Months
Maintenance Procedures Every 2000 Hours or 1 Year9 topics
- Steer Wheel Hub Bearings
- Brake System Accumulator
- Lift System Accumulator (Optional)
- Engine Cleaning
- Engine and Transmission Mounting
- Engine Valve and Injector Adjustment
- Turbo Charger
- Transmission Clutch Calibration
- Inch Pedal Sensor Calibration
Maintenance Procedures every 3000 Hours or 3 Years2 topics
- Hydraulic System Oil and Hydraulic System Suction Filter
- Hydraulic Return Filters
Maintenance Procedures Every 5000 Hours2 topics
- Container Attachment (F117)
- Air Conditioning
Maintenance Procedures Every 6000 Hours or 2 Years4 topics
- Vibration Damper
- Fan Belt and Tensioner
- Fan Drive Idler Pulley
- Fan Hub
Maintenance Procedures Every 10,000 Hours or 5 Years1 topic
- High Pressure Hydraulic Oil Filter
Lift and Tilt System Leaks Check2 topics
- Lift System
- Tilt System
Pneumatic Tires and Wheels5 topics
- Remove Wheels From Lift Truck
- Remove Tire From Wheel
- Install Tire on Wheel
- Add Air Pressure to Tires
- Install Wheels on Lift Truck
Table 1. Condition Check
Table 2. Daily Inspections − Fluid Level Check
Table 3. Daily Inspections − Checks With the Engine Running
Table 4. First Inspection After First 100 Hours of Operation
Table 5. Periodic Maintenance Schedule − Inspect and Adjust
Table 6. Periodic Maintenance Schedule − Lubricate
Table 7. Periodic Maintenance Schedule − Change
Table 8. Container Attachment Maintenance- Inspect and Adjust
Table 9. Container Attachment Maintenance - Lubricate
Table 10. Container Attachment Maintenance − Replace
Table 11. Valve and Injector Adjustment Specifications
Table 12. Injector and Valve Measurement Sequence
Transmission operation and diagnostics
Description of Operation4 topics
- Hydraulic Operation
- Variable Force Solenoids
- Speed Engagement
- Cooling and Lubrication
Control System4 topics
- APC200 Controller
- Transmission Control Valve
- Pressure Specifications
- Pressure, Speed, and Temperature Sensors
Transmission Test and Calibration4 topics
- Precautions
- Stall Test
- Clutch Filling Calibration
- Inching Calibration
Electrical Specifications
APC200 Display Information11 topics
- General Information Group
- Fault Codes
- Indication of Protection Modes
- Test Function Group
- Digital Input Test
- Analog Input Test
- Speed Sensor Test
- Output Test
- Voltage Test
- Calibration Group
- Torque Specifications for Lubricated or Plated Screw Threads
Table 1. Activated Solenoids and Gear Selection
Table 2. Port Numbers
Table 3. Speed Sensor Test Values
Table 4. Temperature Sensor (In Speed Sensor) Resistance Versus
Table 5. General Information Group
Table 6. Digital Input Test
Table 7. Analog Input Test
Table 8. Speed Sensor Test
Table 9. Output Test
Table 10. Voltage Test
Table 11. APC200 Wire Number to Hyster Wire Number Conversion
Table 12. Grade 5
Table 13. Grade 8
Table 15. Elastic Stop Nut Torque
Table 16. O-ring Port Plug Torque Chart
Table 17. Pipe Plug Torque Chart
Table 18. Pipe Plug Torque Chart
Hydraulic System7 topics
- Hydraulic Plate
- Hydraulic Pumps
- Cab Manifold
- Accumulator Charge Disabling Solenoid (ACDS)
- Heat Exchanger System
- Steering Control System
- Brake System
Hydraulic Pump Repair1 topic
- Pump Output Check
Cab Manifold2 topics
- Disassemble Valves and Pressure Switches
- Assemble Valves and Pressure Switches
Lift and Lower Circuit4 topics
- Description
- Operation
- Repairs
- Checks and Adjustments
Tilt Control Circuit
Attachment Circuit Valves
Other Hydraulic Components17 topics
- Description and Operation
- Hydraulic Hose Repair
- Hydraulic Pumps Output at 2100 rpm (Governed Speed)
- Relief Valves (Approximate Operating Pressures)
- Check Port Pressures
- Main Hydraulic Filters
- Tank Capacity
- Remote Control Valves
- Attachment Control Valve
- Carriage Solenoid Valve
- Lift and Lower Circuit
- Tilt Circuit
- Attachment Circuit Valves
- Other Hydraulic Components
- Accumulator Circuit
- MPa ( 725 psi) Pilot Circuit
- Park Brake Circuit
Table 1. Brake Treadle Settings
Table 2. Gauge Ranges
Table 3. Pressure Settings
Operator's Cab
Cab Repair5 topics
- Rear Cab Assembly
- Bottom Cab Assembly
- Raising and Lowering
- Cab Repair
- Oil Filling for Tilt System
Inching/Brake and Brake Pedals4 topics
- Brake Pedal, Adjust
- Inching Pedal, Adjust
- Inching Pedal Sensor, Adjust
- Inching Cable, Adjust
Throttle Pedal Sensor Adjustment2 topics
- Cable Alignment
- Check
Seat Assembly Removal
Power-Assist Armrest
Steering Column Repair
Window Wipers Replacement4 topics
- Window Wiper Assembly, Replace
- Front Window Wiper Motor Assembly, Replace
- Rear Window Wiper Motor Assembly, Replace
- Top Window Wiper Motor Assembly, Replace
Window Washer Motors and Pumps1 topic
- Window Wiper and Washer Operating Switches
Window Replacement4 topics
- Front Window, Replace
- Rear Window, Replace
- Top Window, Replace
- Door Window, Replace
Heater and Air Conditioning Assembly6 topics
- Heater Parts, Replace
- Heat Control Knob/Switches
- Heat Control Knob/Cable
- Air Control Knob/Cable
- Air Filter, Replace
- Air Conditioning Condenser Fan(s)
Instruments, Switches, and Controls2 topics
- Switches
- Controls
Fuses, Relays, and Power Sources4 topics
- Fuse Panel
- Fuses
- Relays
- Power Sources
Label Replacement
Frame
Counterweight Repair
Covers
Floor Plates, Handrails, and Steps
Hydraulic Tank Repair2 topics
- Other Methods of Preparation for Repair
- Suction Screen and Inspection Cover
Fuel Tank Repair
Exhaust System Repair
Engine Repair
Table 1. Counterweight Weights (Up to February 2007)
Table 2. Counterweight Weights (February 2007 and Up)
Table 3. Counterweight Weights
Multiple Aligned Cooling System5 topics
- Radiator
- Radiator Cap
- Thermostat
- Water Pump
- Fan and Fan Shroud
Cooling System Checks1 topic
- Exhaust Leaks
Cooling System Repair
Core Repair
Radiator Cleaning2 topics
- Drain
- Fill
Electrical System
Warning Devices
Meters, Senders, and Switches
Capacities and Specifications
Counterweight Weights
Carriage Weights
Vehicle Weight
Capacities
Engine Specifications (Cummins QSM11)
Mast Weights
Lifting and Lowering Speeds
Tires
Forks
Hydraulic System Specifications13 topics
- Control Valves
- Electrical System
- Counterweight (Fabricated)
- Counterweight (Secondary)
- Counterweight (Slab)
- Drive Axle
- Wheel Bearing Adjusting Nut
- Differential
- Transmission
- Torque Converter
- Steering
- Wheel Nuts
- Carriages (All)
Table 1. Up to February 2007
Table 2. February 2007 and Up
Table 3. March 2007 and Up
Table 4. Slab Counterweight (Up to February 2007)
Assembly Guide
List of All Special Tools and Equipment Needed for the Assembly
General Considerations Before Starting the Job
Weight and Dimensions
Loading Procedures2 topics
- Loading Complete Truck or Basic Truck on a Transport
- Loading Disassembled Components
Unloading Procedures2 topics
- Unloading Complete Truck or Basic Truck From Transport
- Unloading Disassembled Components
How to Move a Disabled Lift Truck1 topic
- How to Tow the Lift Truck
Components Preparation Before Assembly
Wheels Check2 topics
- Air Pressure
- Wheel Nut Torque
Installation of the Exhaust Extension Pipe
Mast Preparation2 topics
- Mast
- Mast Label Placement
Mast Installation2 topics
- Tilt Cylinder Pin Installation
- Truck Header Hoses and Electrical Cable Connections
Lights Installation - Operator Compartment
General Procedures After Assembly
Hydraulic Oil Check
Lubrication Points
Pre-Delivery Inspection1 topic
- Empty Seat Engine Shut Down
Check Points5 topics
- Checkpoint 1
- Checkpoint 2
- Checkpoint 3
- Checkpoint 4
- Checkpoint 5
General Truck Installation Procedures
Table 1. Basic Truck A917
Table 2. Basic Truck B917
Table 3. Mast
Table 4. Carriage
Table 5. Container Attachment
Table 6. Forks
Cab Heater (Prior to Oct. 2008)
Aurora Heater and Air Conditioner8 topics
- Heater System
- Heater System Repair
- Heater Assembly Parts, Replace
- Push/Pull Cable, Replace
- Electric-Operated Heater Control and Fan Control
- Cable-Operated Heater Control and Air Control
- Air Conditioning Switch
- Technical Detail
Table 1. Air Conditioning Specifications
Aurora_AC5 topics
- Compressors - Applications, Conditions of Use and Liability
- Troubleshooting
- Technical modifications reserved
- Condenser unit, 24V
- 1Safety advices
Inside this manual
Real pages from this service manual (1,382 pages). Open the sample pages (PDF, 212 KB)
- Specifications, page 226: Table 11. Cotter Pin Dimensional Data
- Diagram, page 646: Diagrams, Schematics, or Arrangements
- Troubleshooting, page 1,108: General
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,382 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).