Hyster H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) (F117) Heavy Duty Forklift Service Manual

Name: Hyster H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) (F117) Heavy Duty Forklift Service Manual
Brand: MidWestTech
SKU: 1616023
Price: 139.71 USD
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1,394 pages · Publication 1616023

$139.71

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Models: H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) (F117)
Manual type: Service Manual
Pages: 1,394
Publication: 1616023
Condition: Brand new

Hyster H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) (F117) Heavy Duty Forklift Service Manual, publication 1616023

What's inside

From the manual's own table of contents: 196 sections, 686 entries. See sample pages (PDF, 215 KB)

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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

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 196 sections

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

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

Operator's Cab

Cab Repair5 topics

Rear Cab Assembly
Bottom Cab Assembly
Cab Repair
- Remove
- Install

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 Adjustment5 topics

Cable Alignment
- Engine Side
- Pedal Housing Side
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 Assembly10 topics

Heater Parts, Replace
Heat Control Knob/Switches
Heat Control Knob/Cable
- Adjust
Air Control Knob/Cable
- Adjust
Air Filter, Replace
Air Conditioning Condenser Fan(s)
- Remove
- Install

Instruments, Switches, and Controls2 topics

Switches
Controls

Fuses, Relays, And Power Sources4 topics

Fuse Panel
Fuses
Relays
Power Sources

Label Replacement

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 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

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

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

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 Repair

Covers

Floor Plates, Handrails, and Steps

Hydraulic Tank Repair9 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 Repair2 topics

Remove
- Install

Engine Repair

Table 1. Counterweight Weights

Hydraulic Plate11 topics

Hydraulic Oil Supply
Manifold, Section 1 of Hydraulic Plate
Main Control Valve, Section 2 of Hydraulic Plate
- Description
- Operation
Return Manifold, Section 3 of Hydraulic Plate
Brake Manifold, Section 4 of Hydraulic Plate
- Cooling Circuit
- Service Brake
- Parking Brake
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 Plate6 topics

Auxiliary Section
- Lift Section
- Lift/Tilt Section
- Auxiliary Section
- Lift Section
- Lift/Tilt Section

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 Senders5 topics

Instrument Panel Meters, Indicators, and LCD Display
Connector
- Seat Switch Logic
- Central Warning Light Output
- Buzzer Output

Instrument Panel Component Replacement4 topics

Instrument Panel
- Remove
Light
- Replace

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

Electrical System

Warning Devices5 topics

Description
- Operator-Controlled Air Horn
- Reverse Warning Horns/Lights
- Warning Lights
- Replace

Meters, Senders, and Switches

Diagrams

Periodic Maintenance7 topics

Serial Number Data
How to Move 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 Daily36 topics

How to Make Checks With the Engine Stopped
- Warning and Safety Labels
- Wheels, Tires and Tire Pressure
- Wheel Nuts
- Mast, Carriage, and Attachments
- Forks
- Header Hose Assembly
- Pre-Cleaner for Air Filter
- Hydraulic Tank Breather
- Fuel, Oil, or Coolant Leaks
- Air Intake Piping and Charge Air Piping
- Drive Belt
- Engine Compartment
- 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
- Engine Air Filter
- Coolant Level
- Main Hydraulic Return Line Filter
- Brake Return Line 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 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 Months5 topics

Parking and Service Brakes
Coolant Quality
Operator's Cab Door Hinges
- Steer Wheel Hubs Fill
Transmission Oil and Oil Filter

Maintenance Procedures Every 1500 Hours or 6 Months

Maintenance Procedures Every 2000 Hours or 1 Year10 topics

Steer Wheel Hub Bearings
Brake System Accumulator
Lift System Accumulator (Optional)
Engine Cleaning
Engine and Transmission Mounting
Engine Valve and Injector Adjustment
- Adjust
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 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. 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

Capacities and Specifications

Counterweight Weights

Container Attachment Weights

Carriage Weights

Vehicle Weights

Capacities

Engine Specifications (Cummins QSM 11)

Mast Weights

Lifting and Lowering Speeds

Tires

Hydraulic System Specifications13 topics

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

Transmission operation and diagnostics

Description of Operation4 topics

Hydraulic Operation
Variable Force Solenoids
Speed Engagement
Cooling and Lubrication

Control System14 topics

APC200 Controller
- Self Test
- Protection Modes
- Fault Codes
- Fault Log Mode
- Fault Identification
Transmission Control Valve
- Hydraulic Control Valve Repair
- Pressure Check
Pressure Specifications
Pressure, Speed, and Temperature Sensors
- Pressure Switch
- Speed Sensor
- Temperature Sensors

Transmission Test and Calibration12 topics

Precautions
Stall Test
- Description
- Stall Test Procedure
Clutch Filling Calibration
- Description
- Procedure
Inching Calibration
- Description
- Brake and Inching Pedal Adjustment
- Inching Pedal Sensor Adjustment
- Inching Pedal Sensor Calibration

Electrical Specifications

APC200 Display Information15 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
- Calibration Mode
- Clutch Filling Calibration
- Heat Up Mode
- Inching Pedal Sensor Calibration
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 System11 topics

Hydraulic Plate
Hydraulic Pumps
Cab Manifold
- Oil Cooled Brakes (Service Brakes)
- Lift/Tilt Functions
- Over Lower Interrupt
- Lift Interrupt
Accumulator Charge Disabling Solenoid (ACDS)
Heat Exchanger System
Steering Control System
Brake System

Hydraulic Pump Repair7 topics

Tandem Gear Pump
- Tri-Section Gear Pump
- Tandem Gear Pump
- Tri-Section Gear Pump
Pump Output Check
- First Method
- Second Method

Cab Manifold2 topics

Disassemble Valves and Pressure Switches
Assemble Valves and Pressure Switches

Lift and Lower Circuit9 topics

Operation
- Lift Circuit
- Lowering
- Lowering Control Valves
Repairs
- General
- Remote Control Valve
- Lift Manifold
Checks and Adjustments

Tilt Control Circuit7 topics

Tilt /Lift Spool
- Relief Valves in Main Control Valve
- Relief Valves, Tilt Lock
- General
- Relief Valves, Tilt Lock, Disassemble
- Clean and Inspect
- Checks and Adjustments

Attachment Circuit Valves2 topics

Selector Valves Auxiliary Functions
- Carriage Solenoid Valve

Inside this manual

Real pages from this service manual (1,394 pages). Open the sample pages (PDF, 214 KB)

Sample pages from the Hyster H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) (F117) Heavy Duty Forklift Service Manual: Specifications, Diagram, Troubleshooting

Specifications, page 226: Table 11. Cotter Pin Dimensional Data
Diagram, page 772: Diagrams, Schematics, or Arrangements
Troubleshooting, page 1,129: APC200 FAULT CODES

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, 1,394 pages

Quantity one is the manual described above.

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