Hyster H800-970E, H1050EH (D117) Forklift Truck Service Manual

Name: Hyster H800-970E, H1050EH (D117) Forklift Truck Service Manual
Brand: MidWestTech
SKU: 1453783
Price: 89.59 USD
Availability: InStock

884 pages · Publication 1453783

$89.59

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Models: H800-970E, H1050EH (D117)
Manual type: Service Manual
Pages: 884
Publication: 1453783
Condition: Brand new

Hyster H800-970E, H1050EH (D117) Forklift Truck Service Manual, publication 1453783

What's inside

From the manual's own table of contents: 184 sections, 584 entries. See sample pages (PDF, 265 KB)

Search the contents

Cooling System

Safety Precautions Maintenance and Repair

General

Description5 topics

Radiator
Radiator Cap
Thermostat
Water Pump
Fan and Fan Shroud

Cooling System Checks1 topic

Exhaust Leaks

Radiator Cleaning3 topics

Drain
Clean
Fill

Troubleshooting

Four-Speed Powershift Transmission

Automatic Powershift Control2 topics

Transmission Control System
Transmission Control Lever

Mechanical Description and Operation23 topics

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

Hydraulic Description and Operation9 topics

Sump, Filter, and Pump
Transmission Charge Pump
- Pressure Regulator Valve
- Relief Valve
Transmission Control Valve
- Solenoid Valves
- Direction Spools
- Range Spools
- Modulator Valves

Table 1. Gear, Solenoid, and Clutch Selections

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 Repair19 topics

Remove, Transmission Only
Remove, Transmission and Engine Assembly
Transmission, Disassemble
- Output Shaft, Disassemble and Assemble
- Fourth-Speed Shaft, Disassemble and Assemble
- Third-Speed Shaft, Disassemble and Assemble
- Forward Shaft and Clutch, Disassemble and Assemble
- Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem
- First-Speed Shaft and Clutch, Disassemble and Assemble
- Input Shaft, Disassemble and Assemble
Speed Sensor, Install
Transmission, Clean and Inspect
Transmission, Assemble
Control Valve
- Clean and Inspect
- Assemble and Install
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 Check3 topics

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

Planetary Gear Axle

Show all 184 sections

Operation

Planetary Gear Axle Repair5 topics

Remove
Disassemble
- Planetary Axle, Disassemble
Assemble and Install
- Planetary Axle, Assemble

Torque Specifications

Table 1. Axle-to-Frame Fasteners

Table 2. Standard Torque Values for Axle Fasteners

Table 3. Drive Wheel Nut Torque

Differential

Differential Repair20 topics

Differential Carrier From Axle Housing, Remove
- Differential and Ring Gear From Differential Carrier, Remove
- Drive Pinion and Pinion Carrier From Differential Carrier, Remov
- Differential and Ring Gear Assembly, Disassemble
- Drive Pinion and Pinion Carrier, Disassemble
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

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 Pumps2 topics

Flow Control Valve
Relief Valve

Hydraulic Gear Pump Repair1 topic

Inspect

Pump Output Check2 topics

Method No. 1
Method No. 2

Hydraulic System Air Check

Tilt Cylinders

Tilt Cylinder Repair4 topics

Tilt Cylinders With O-Ring or Single-Lip Seals
- Tilt Cylinders for XM and XMS Models
- Tilt Cylinders for H700-800A and Early Model H700-920B
- Tilt Cylinders Using Chevron Packing

Tilt Cylinder Leak Check

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment2 topics

Piston Rod Nut
Retainer

Table 1. Movement Rates (Maximum) for Tilt Cylinders

Instrument Panel Indicators and Senders14 topics

Steering Column Gauges, Meters, and Indicators
LED Display Panel
- Battery Discharge Indicators
- Brush Wear Indicators
- Motor Temperature Indicators
LX Series Display Panel
- Hourmeter Functions
- Battery Indicator Function
- Status Code Function
ZX Series Display Panels
- Display Panel
- Basic Display Panels
- Performance Display
- Brush Wear Indicators

Adjustments - General

Replacement - General Information

Meter Replacement

Sender Replacement2 topics

Fuel Level Sender
Pressure and Temperature Sender

ITW Display Panel Replacement

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl7 topics

Display Panel Assembly, Replace
Indicator LEDs
Battery Indicators
Digital Display (Performance Display Panel Only)
Status Code or Performance Level Switches and Indicator LEDs (Pe
Basic Display Panel, Replace Parts
Performance Display Panel, Replace Parts

Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace4 topics

Remove and Replace
Meter Specifications
Sender Specifications
Meter

Metric and Inch (SAE) Fasteners6 topics

Threaded Fasteners
Nomenclature, Threads
Strength Identification
Cotter (Split) Pins
Fastener Torque Tables
Conversion Table

Table 1. Bolts and Screws

Table 2. Studs and Nuts

Table 3. Torque Nuts

Table 4. Torque Nuts With Nylon Insert

Table 5. Torque Values for Metric Fasteners*

Table 6. Torque Values for Inch Fasteners*

Table 7. Conversion Table for Metric and English units

Table 8. Cotter Pin Dimensional Data

Diagrams

Periodic Maintenance6 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

Maintenance Schedule

Maintenance Procedures Every 8 Hours or Daily33 topics

How to Make Checks With Engine Stopped
- Tires and Wheels
- Forks
- Inspection of Forks, Mast, and Lift Chains
- Precleaner for Air Filter
- Air Filter
- Safety Labels
- Operator Restraint System
- Steering Column Latch
- Fuel, Oil, or Coolant Leak Check
- Drive Belt
- Engine Oil
- Cooling System
- Hydraulic System Oil
- Hydraulic Oil Filters
- Hydraulic Filter
- Battery
- Splash Fuses
How to Make Checks With Engine Running
- Engine Fault Codes
- Gauges, Lights, Horn, Fuses, and Relays
- Engine Oil Pressure
- Electrical System
- Transmission Oil
- Steering System
- Service Brakes
- Parking Brake
- Fuel System
- Primary Fuel Filter
- Control Levers and Pedals
- Lift System Operation
- Attachments
How to Add Fuel to Lift Truck

Maintenance Procedures Every 250 Hours or Each Month16 topics

Engine Oil and Filter
Oil Filter for Oil Cooled Brakes
Transmission
Coolant Filter
Lift Chains
Drive Shaft
Steering Axle Tie Rod Pins
Drive Axle and Differential
Heater Air Filter
Wheel Nuts
Mast Pivots, Sliding Surfaces
Sideshift Carriage
Fork Guides
Tilt Cylinder Pins
Shift Control Lever
Dedicated Carriage and Container Attachments

Maintenance Procedures Every 500 Hours or 2 Months4 topics

Forks
Idle Speed
Governed Speed
Hydraulic Tank Breather

Maintenance Procedures Every 1000 Hours or 6 Months12 topics

Steer Wheel Bearing Nut
Change Transmission Oil
Fuel Filter
Chain Sheaves
Mast and Carriage Load Rollers
General Lubrication
Injection Pump Timing
Valve Adjustments
Steering Axle Kingpins
Disc Brake Assemblies
- Clean
- Inspect

Maintenance Procedures Every 2000 Hours or Yearly6 topics

Change Hydraulic Oil and Filters
Cooling System
Change Drive Axle and Differential Oil
Change Grease in Hub Bearings of Steer Wheels
Steering Axle Pivots
PCV Valve

Safety Procedures When Working Near Mast

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. Maintenance Schedule

Table 2. Maintenance Schedule, Container Attachment Until Mid 19

Table 3. Maintenance Schedule, Dedicated Container Attachment Af

Table 4. Maintenance Schedule, Fork Mounted Container Attachment

Table 5. Maintenance Schedule, Gantry Container Attachment After

Table 6. Error Code Descriptions

Table 7. Steer Wheel Nut Torque Specifications

Oil-Cooled Brakes1 topic

Description

Description and Operation7 topics

Accumulator Charge Valve
Pressure Reducing Valves
Brake Pedal Valves
- Operation
Parking Brake
Service Brakes
Auxiliary Brake (D117 only)

Pressure Switch Replacement

Accumulator Charge Valve Repair1 topic

Adjust

Accumulator

Relay Valve Repair

Shuttle Valve Repair

Brake Pedal Valves (Treadle Valves) Repair

Inching Valve Repair

Brake System Air Removal

Table 1. Accumulator Charge Valve Pressures

Table 2. Brake Treadle Settings

Electrical System/Lights

Alternator8 topics

Remove and Disassemble
Inspect, Test, and Repair
- Rotor
- Rectifiers and Diode Set
- Drive End Frame
- Brush End Frame
- Brushes and Brush Holder Assembly
- Stator

Meters, Senders, and Switches

Capacities and Specifications

Counterweights Weights

Container Attachment Weights

Carriage Weights

Vehicle Weights

Capacities

Electrical System

Engine Specifications

Mast Weights

Lifting and Lowering Speeds

Tires

Forks

Hydraulic System Specifications9 topics

Control Valves
Electrical System
Counterweight
Drive Axle
Disc Brakes
Differential
Steering
Carriages (All)
Attachment - 20 to 40 Foot

Disc Brakes2 topics

Operation
Auxiliary Brake

Pressure Reducing Valves Repair

Shuttle and Sequence Valves Repair

Service Brake Calipers Repair

Frame

Counterweight Repair

Fenders Repair

Hood and Ballast Cover6 topics

Hood
- Remove
- Install
Ballast
- Remove
- Install

Floor Plates and Covers

Hydraulic Tank Repair6 topics

Repair
- Small Leaks
- Large Leaks
- Steam Method
- Chemical Solution Method
Other Methods of Preparation for Repair

Fuel Tank Repair

Radiator Repair

Engine Repair

Operator Compartment Repair

Gauges and Switches Repair

Window Wipers Repair2 topics

Single Arm Wipers
Double Arm Wipers

Window Washer Motor/Pumps

Fuse Panel

Heater Assembly Repair2 topics

Heater Control Panel Assembly
- Blower and Core Assemblies

Door Handle Assembly

Door Retainer Assemblies

Window Replacement4 topics

Front and Rear Windows
Lower Door Windows
Upper Door (Slider) Windows
Top Window

Operator Restraint System Repair

Label Replacement

Hydraulic Plate8 topics

Hydraulic Oil Supply
Manifold, Section 1 of Hydraulic Plate
Two-Spool and Single-Spool Main Control Valves, Section 2 and 3
Flow Amplifier, Section 4 of Hydraulic Plate
Return Manifold, Section 5 of Hydraulic Plate
Hydraulic Filter
Relay Valve (D117 Only)
Manual Override (E008 Only)

Main Manifold Repair1 topic

Valves and Pressure Switches

Main Control Valves Repair1 topic

Single Spool and Two Spool

Flow Amplifier Repair

Hydraulic Hose Repair

Torque Values

Measurements and Adjustments2 topics

Measurements
Adjustments

Table 3. Pressure Settings

Hydraulic System9 topics

Hydraulic Plate
Main Control Valves
Remote Control Valve
Lift Manifold
Directional Control Valve
Carriage Solenoid Valves
Heat Exchanger System
Steering Control System
Brake System

Lift and Lower Circuit16 topics

Operation
- Lift Circuit, Normal Speed (Heavy Load)
- Lift Circuit, High Speed (Light Load)
- Lowering
- Lowering Control Valves
Repairs
- General
- Hydraulic Plate, Remove
- Remote Control Valve
- Main Control Valves
- Lift Manifold
Checks and Adjustments
- Pilot Relief Pressure, Check
- Main Control Valves Relief Pressure, Check
- Lift Manifold, Check
- Remote Control Valve, Adjust

Tilt Control Circuit8 topics

Tilt Spool
- Relief Valves in Main Control Valve
- Relief Valves, Tilt Lock
- General
- Main Control Valve (Two-Spool), Replace
- Relief Valves, Tilt Lock, Disassemble
- Clean and Inspect
- Main Control Valve Relief Pressure, Check

Attachment Circuit Valves5 topics

Directional Control Valve
- Carriage Solenoid Valve
- Directional Control Valve
- Return Control Valves
- Carriage Solenoid Valve

Inside this manual

Real pages from this service manual (884 pages). Open the sample pages (PDF, 264 KB)

Sample pages from the Hyster H800-970E, H1050EH (D117) Forklift Truck Service Manual: Diagram, Troubleshooting, Specifications

Diagram, page 389: Schematics
Troubleshooting, page 480: Troubleshooting
Specifications, page 584: Description and Operation

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, 884 pages

Quantity one is the manual described above.

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Ships in 1 business day.

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