Hyster E117 (H1050HD-CH, H1150HD-CH) Heavy Duty Forklift Service Manual

Name: Hyster E117 (H1050HD-CH, H1150HD-CH) Heavy Duty Forklift Service Manual
Brand: MidWestTech
SKU: 1546428
Price: 139.93 USD
Availability: InStock

1,378 pages · Publication 1546428

$139.93

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.

Models: E117 (H1050HD-CH, H1150HD-CH)
Manual type: Service Manual
Pages: 1,378
Publication: 1546428
Condition: Brand new

Hyster E117 (H1050HD-CH, H1150HD-CH) Heavy Duty Forklift Service Manual, publication 1546428

What's inside

From the manual's own table of contents: 204 sections, 457 entries. See sample pages (PDF, 234 KB)

Search the contents

Four-Speed Powershift Transmission

Safety Precautions Maintenance and Repair

General

Automatic Powershift Control2 topics

Transmission Control System
Transmission Control Lever

Mechanical Description and Operation9 topics

General
Torque Converter
Clutch Assemblies
Transmission Operation in Neutral
Input Shaft, Forward Shaft, and Clutch Assembly
Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli
Third-Speed Shaft, Gear, and Clutch Assembly
Fourth-Speed Shaft and Clutch
Output Shaft

Hydraulic Description and Operation3 topics

Sump, Filter, and Pump
Transmission Charge Pump
Transmission Control Valve

Table 1. Solenoid Controls

Torque Converter Repair9 topics

Torque Converter, Remove
Torque Converter, Disassemble
Clean and Inspect
Torque Converter, Assemble
Torque Converter (Turbine) Housing, Disassemble
Relief Valve for Lube Pressure, Disassemble and Assemble
Oil Sealing Rings Sleeve, Replace
Torque Converter Housing, Assemble
Torque Converter, Install

Transmission Repair10 topics

Remove, Transmission Only
Transmission and Engine Assembly, Remove
Transmission, Disassemble
Speed Sensor, Install
Transmission, Clean and Inspect
Transmission, Assemble
Control Valve
Install, Transmission
Install, Transmission and Engine Assembly
Clean Oil System of Transmission After Major Repair

Automatic Powershift Control (APC 100)2 topics

Functional Description
Fuses

First-Speed Shaft Bearings Adjustment

Torque Converter Stall Speed Check

Transmission Oil Pressures Check2 topics

Clutch Pressures Check
Torque Converter (Torque Converter Regulator) Oil Pressure Check

Troubleshooting1 topic

Transmission Controller (APC 100)

Table 1. Flange Nut Torque

Table 2. APC 100 Control Module (Pin Connections)

Table 3. Hobbs Gear Selector Connections

Table 4. Example Torque Values at Dimensions Shown

Table 5. Transmission Pressures

Differential

Description

Differential Repair4 topics

Remove
Disassemble
Assemble
Install

Specifications

Table 1. Ring Gear Backlash Adjustment Specifications

Show all 204 sections

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

Table 1. Accumulator Pressures

Service Brake1 topic

B222 Only

Repair2 topics

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

Hydraulic System6 topics

Hydraulic Plate
Hydraulic Pumps
Cab Manifold
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 Components7 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

Torque Specifications10 topics

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

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 Senders3 topics

Instrument Panel Meters, Indicators, and LCD Display
Error Code 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. Switches Description

Table 3. Pin Description

Table 4. Sender Description

Operator's Cab

Cab Repair3 topics

Rear Cab Assembly
Bottom Cab Assembly
Cab Repair

Declutch (E117), Inching (F117), and Brake Pedals4 topics

Brake Pedal, Adjust
Declutch Pedal, Adjust (E117 Only)
Inching Pedal, Adjust (F117 Only)
Inching Pedal Sensor, Adjust (F117 Only)

Throttle Pedal Sensor Adjustment3 topics

Cable Alignment
Check
Adjust

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 Sources3 topics

Fuse Panel
Relays
Power Sources

Label Replacement

Tilt Cylinders

Tilt Cylinder Repair

Tilt Cylinder Leak Check

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment

Table 1. Movement Rate (Maximum) for Tilt Cylinders

Parking Brake

Parking Brake Valve Replacement

Parking Brake Caliper Repair1 topic

Bleed Brakes

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

Frame

Counterweight Repair3 topics

Main Counterweight (Cast)
Rear Counterweight (Cast)
Main Counterweight (Fabricated)

Covers

Floor Plates, Handrails, and Steps

Hydraulic Tank Repair2 topics

Other Methods of Preparation for Repair
Suction Screen and Inspection Cover

Fuel Tank Repair

Engine Repair

Periodic Maintenance3 topics

Serial Number Data
How to Move Disabled Lift Truck
How to Put Lift Truck on Blocks

Maintenance Schedule1 topic

Spreader Maintenance

Maintenance Procedures Every 8 Hours or Daily3 topics

How to Make Checks With Engine Stopped
How to Add Fuel to Lift Truck
How to Make Checks With Engine Running

First Inspection After First 100 Hours of Operation6 topics

Engine Oil Filter
Drive Axle and Differential
Lift Chains
Transmission Oil Filter
Air Conditioning
Steer Wheel Hubs

Maintenance Procedures Every 250 Hours Or Monthly2 topics

Twist Locks
Gantry Carriage and Container Attachments

Maintenance Procedures Every 500 Hours or 3 Months11 topics

Drive Belt
Hydraulic Return Line Oil Filter
Wheel Nuts
Heater Air Filter
Steering Axle Kingpins
Steering Axle Tie Rods
Drive Shaft
Steering Axle Pivots
Mast and Carriage Load Rollers
Mast Pivots, Sliding Surfaces
Sideshift Carriage

Maintenance Procedures Every 500 Hours or 6 Months4 topics

Fuel Filter
Engine Oil and Filter
Oil Filter for Oil Cooled Brakes (Brake Filter)
Change Transmission Oil

Maintenance Procedures Every 1000 Hours or 6 Months5 topics

Drive Axle and Differential Oil
Service Brake System
Brake System Accumulator
Hub Bearings, Steer Wheels
General Lubrication

Maintenance Procedures Every 1500 Hours or 1 Year6 topics

Engine
Water Pump
Turbocharger
Engine Mounting Bolts
Air Leaks, Air Intake and Exhaust
Valve and Injector Adjustments

Maintenance Procedures Every 2000 Hours or 1 Year2 topics

Hydraulic High Pressure Oil Filter
Parking Brake Assembly

Maintenance Procedures Every 4000 Hours or 2 Years1 topic

Hydraulic Suction Oil Filters

Maintenance Procedures Every 5000 Hours1 topic

Container Attachment

Maintenance Procedures Every 6000 Hours or 2 Years4 topics

Vibration Damper
Fan Drive Idler Pulley
Fan Hub
Cooling System Fluid

Safety Procedures When Working Near Mast

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. Daily Inspections − 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 - Lubricate

Table 9. Container Attachment Maintenance − Replace

Table 10. Valve and Injector Adjustment Specifications

Table 11. Injector and Valve Measurement Sequence

Capacities and Specifications

Counterweight Weights

Container Attachment Weights

Carriage Weights

Vehicle Weights

Capacities

Electrical System

Engine Specifications (Cummins QSM 11)

Mast Weights

Lifting and Lowering Speeds

Tires

Hydraulic System Specifications12 topics

Control Valves
Electrical System
Counterweight (Cast)
Counterweight (Fabricated)
Counterweight (Slab)
Drive Axle
Wheel Bearing Adjusting Nut
Differential
Transmission
Steering
Carriages (All)
Attachment - 20- to 40-Foot

Table 1. Fabricated Type

Table 2. Cast Type

Description of Operation8 topics

Torque Convertor, Pump Drive, and Pressure Regulating Valve
Input Shaft and Directional Clutches
Range Clutches
Output Section
Transmission Controls
Electric Solenoid Controls
Transmission Specifications
Speed Sensor Installation

Low (1st) Speed Shaft Bearing Adjustment

Control Valve Repair2 topics

Disassemble and Assemble
Limp Home Function

Stall Test

Transmission Oil Pressure Check1 topic

Pressure and Temperature Specifications

Electrical Wiring and Specifications2 topics

Electrical Wiring
Electrical Specifications

Hydraulic Cooler and Filter Lines Specifications1 topic

Torque Specifications for Lubricated or Plated Screw Threads

Table 3. Example Torque Values at Dimensions Shown

Table 4. Speed and Energized Wires

Table 5. Wire Numbers and Color Codes

Table 6. Grade 5

Table 7. Grade 8

Table 9. Elastic Stop Nut Torque

Table 10. O-ring Port Plug Torque Chart

Table 11. Pipe Plug Torque Chart

Diagrams

Multiple Aligned Cooling System4 topics

Radiator
Radiator Cap
Thermostat
Fan and Fan Shroud

Cooling System Checks1 topic

Exhaust Leaks

Cooling System Repair

Core Repair

Radiator Cleaning2 topics

Drain
Fill

Mast2 topics

Lifting
Lowering

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

Warning Devices

Meters, Senders, System Warning Lights, and Switches

Alternator

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 (1,378 pages). Open the sample pages (PDF, 233 KB)

Sample pages from the Hyster E117 (H1050HD-CH, H1150HD-CH) Heavy Duty Forklift Service Manual: Specifications, Diagram, Troubleshooting

Specifications, page 751: Torque Specifications
Diagram, page 940: Diagrams, Schematics, or Arrangements
Troubleshooting, page 1,087: Maintenance Monitor (A222 Only)

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, 1,378 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.

Other editions and similar models

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).