Hyster G117 (H1050HD-16CH, H1150HD-16CH) Container Handler Service Manual
1,321 pages · Publication G117
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- Models
- G117 (H1050HD-16CH, H1150HD-16CH)
- Manual type
- Service Manual
- Pages
- 1,321
- Publication
- G117
- Condition
- Brand new
What's inside
From the manual's own table of contents: 121 sections, 371 entries. See sample pages (PDF, 210 KB)
Differential
Safety Precautions Maintenance and Repair
General
Description
Differential Repair23 topics
- Remove
- Differential Carrier From Axle Housing, Remove
- Differential and Ring Gear From Differential Carrier, Remove
- Drive Pinion and Pinion Carrier From Differential Carrier, Remov
- Disassemble
- Differential and Ring Gear Assembly, Disassemble
- Drive Pinion and Pinion Carrier, Disassemble
- Clean and Inspect
- Assemble
- Pinion, Bearings, and Pinion Carrier, Assemble
- Pinion Bearings, Adjust Preload
- Triple-Lip Seal, Install
- Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)
- Differential and Ring Gear, Assemble
- Differential Gears Rotating Torque, Check
- Differential and Ring Gear Assembly, Install
- Differential Bearings, Preload Adjust
- Ring Gear, Runout Check
- Ring Gear Backlash, Adjust
- Gear Set, Tooth Contact Pattern Check
- Thrust Screw, Install and Adjust
- Install
- Differential Assembly Into Axle Housing, 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
Brake Accumulator
Description and Operation
Accumulator Maintenance6 topics
- Pre-Charge Check
- Pre-Charge Filling
- Clean
- Inspect
- Repair
- Replace
Table 1. Accumulator Pressures
Service Brake1 topic
- B222 Only
Repair18 topics
- General
- Drive Wheels and Tires
- Brake Housing
- Spindle and Brake Cover
- Ground and Polished Parts
- Parts With Rough Finish
- Wet Disc Brake and Axle Assembly
- Face Seals
- Disc
- Parts
- Brake Housings
- Hub Oil Seals
- Spindle and Brake Cover
- Brake Housing
- Drive Wheels and Tires
- Pressure Switch
- Replace
- Accumulator
Brake Pedal Valves (Treadle Valves) Repair6 topics
- Remove
- Clean and Inspect
- Install
- Remove
- Clean and Inspect
- Install
Brake System Air Removal3 topics
- Brake Coolant
- Coolant Change Intervals
- Hydraulic Fluid
Show all 121 sections
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 Repair1 topic
- Low-Mount Fork
Carriage Repair2 topics
- Carriage Side Blocks
- Adjust
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
Operation
Planetary Gear Axle Repair24 topics
- Drive Wheels and Tires
- Drive Axle
- Planetary Gear Carrier
- Ring Gear, Ring Gear Hub, and Wheel Hub
- Hub Oil Seal and Bearings
- Axle Shaft
- Spindle
- Repairing or Replacing Parts
- Welding
- Ground or Polished Parts
- Parts With Rough Finishes
- Axle Assemblies
- Drying Cleaned Parts
- Preventing Corrosion
- Parts Inspection
- Spindle
- Axle Shaft
- Hub Oil Seal and Bearings
- Ring Gear, Ring Gear Hub, and Wheel Hub
- Wheel Bearing Preload
- Planetary Gear Carrier
- Drive Axle
- Wheel Ends
- Drive Wheels and Tires
Table 1. Wheel Bearing Adjustment Torque
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi
Table 3. Standard Torque Values for Axle Fasteners
Frame
Counterweight
Covers
Floor Plates, Handrails, and Steps
Hydraulic Tank9 topics
- Small Leaks
- Large Leaks
- Steam Method
- Chemical Solution Method
- Other Methods of Preparation for Repair
- Suction Screen and Inspection Cover
- Remove
- Clean and Inspect
- Install
Fuel Tank Removal and Replacement
Engine
Exhaust System
Label Replacement
Table 1. Counterweight Weights (G117)
Table 2. Counterweight Weights (B917)
Diagrams
Capacities and Specifications
Counterweight Weights
Basic Truck Weights
Container Attachment Weights
Carriage Weights
Capacities
Electrical System
Engine Specifications
Mast Weights
Lifting and Lowering Speeds
Tire Sizes
Hydraulic System Specification19 topics
- Main Control Valve
- A-Side
- Top-Side
- B-Side
- A and B Side
- Electrical System
- Alternator
- Counterweight (Fabricated)
- Main Counterweight
- Counterweight (Slab)
- Main Counterweight
- Drive Axle
- Wheel Bearing Adjusting Nut PRC-7534
- Differential
- Transmission
- Torque Converter
- Steering
- Wheel Nuts
- Attachment 20 - 40 ft
Periodic Maintenance7 topics
- Serial Number Data
- How to Move a Disabled Lift Truck
- How to Tow Lift Truck
- How to Put Lift Truck on Blocks
- How to Raise Drive Tires
- How to Raise Steering Tires
- How to Clean a Lift Truck
Maintenance Schedule1 topic
- Spreader Maintenance
Maintenance Procedures Every 8 Hours or Daily32 topics
- How to Make Checks With the Engine Stopped
- Warning and Safety Labels
- Wheels, Tires and Tire Pressure
- Wheel Nuts
- Mast, Carriage, Attachments and Frame
- Header Hose Assembly
- Precleaner for Air Filter
- Hydraulic Tank Breather
- Fuel, Oil, or Coolant Leaks
- Radiator Sections for Engine Coolant, Charge Air Cooler, Transmi
- Windshield Washer Fluid
- Hydraulic System Oil
- Engine Oil
- How to Make Checks With Engine Running
- Seat Belt, Seat Rails, and Steering Column
- Gauges, Lights, Horn, Fuses, and Relays
- Windows and Mirrors
- Engine and Transmission Fault Codes
- High Exhaust System Temperature Light
- Engine Air Filter
- Coolant Level
- High Pressure Brake Cooling Filter
- Fuel Level
- Control Levers and Pedals
- Parking Brake
- Service Brakes
- Steering System
- Mast, Carriage, and Attachment
- Signals from the Spreader Control System
- Transmission
- Operator Presence System
- Transmission Oil
First Inspection After First 100 Hours of Operation3 topics
- Lift Chains
- High Pressure Brake Cooling Filter
- Transmission Oil Filter
First Inspection After First 250 Hours Of Operation3 topics
- Steer Wheel Hub, Oil Change and Bearing Adjustment
- Kessler Drive Wheel Hubs, Oil Change and Bearing Adjustment
- Remove Wheels From Lift Truck
Maintenance Procedures Every 250 Hours or 3 Months28 topics
- Warnings and Safety Labels
- Wheels, Tires, and Tire Pressure
- Mast, Carriage, and 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
- Engine Oil Level
- 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
- Attachment
- Signals From the Spreader Control System
Maintenance Procedures Every 500 Hours or 3 Months10 topics
- Steering Axle Tie Rod Pins
- Steer Axle Kingpin
- Steering Axle Pivot
- Attachment Bearing Pads and Bearing Pad Tracks
- Twist Locks
- Stop Cylinders
- Locking Plate for Stop Cylinder
- Hangers
- Slewing Cylinders
- Fork Contact Area With Spreader Pads
Maintenance Procedures Every 500 Hours or 6 Months5 topics
- Header Hose Assembly
- Cab Air Filter
- Coolant Level
- Engine Oil and Oil Filter
- Fuel Filter/Water Separator
Maintenance Procedures Every 1000 Hours1 topic
- 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 Months1 topic
- Axle Tech, Drive Axle and Differential
Maintenance Procedures Every 2000 Hours or 1 Year6 topics
- Drive Shaft
- Brake System Accumulator
- Lift System Accumulator (Optional)
- Engine and Transmission Mounting
- Transmission Clutch Calibration
- Inch Pedal Sensor Calibration
Maintenance Procedures Every 2500 Hours or 12 Months1 topic
- Remove Wheels From Lift Truck
Maintenance Procedures Every 3000 Hours or 3 Years5 topics
- Brake Return Line Filter (G117 Only)
- Hydraulic System Oil and Hydraulic System Suction Filter
- Hydraulic Return Filters
- Wet Brakes Lining Wear
- Turbocharger
Maintenance Procedures Every 5000 Hours10 topics
- Container Attachment
- Air Conditioning
- Engine Valve and Injector Adjustment
- Adjust
- Diesel Particulate Filter (DPF)
- Remove
- Disassemble
- Assemble
- Install
- Automatic Greasing System Filter
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 Main Manifold Filter
Lift and Tilt System Leaks Check2 topics
- Lift System
- Tilt System
Pneumatic Tires and Wheels7 topics
- Remove Wheels From Lift Truck
- Remove Tire From Wheel
- Remove Tire From Five-Piece Wheel
- Install Tire on Wheel
- Install Tire on Five-Piece 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. First Inspection After First 250 Hours of Operation
Table 6. Periodic Maintenance Schedule − Inspect and Adjust
Table 7. Periodic Maintenance Schedule − Lubricate
Table 8. Periodic Maintenance Schedule − Change
Table 9. Container Attachment Maintenance- Inspect and Adjust
Table 10. Container Attachment Maintenance - Lubricate
Table 11. Container Attachment Maintenance − Change
Table 12. Approved Fuels and Engine Oils
Table 13. Valve and Injector Adjustment Specifications
Table 14. Injector and Valve Measurement Sequence
Inside this manual
Real pages from this service manual (1,321 pages). Open the sample pages (PDF, 210 KB)
- Troubleshooting, page 495: Troubleshooting
- Diagram, page 1,135: Diagrams, Schematics, or Arrangements
- Specifications, page 1,235: Pneumatic Tires and Wheels
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, 1,321 pages
Quantity one is the manual described above.
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