Hyster D117 (H36.00-48.00E, -16CH) Service Manual

Description

• Model List:
  • D117 (H36.00-48.00E, -16CH)

• 1. RM0429-(04-1997)-UK-EN
• 1.1. INTRODUCTION
• 1.2. STEERING WHEEL AND COLUMN ASSEMBLY
• 1.3. STEERING CONTROL UNIT
• 1.4. FLOW AMPLIFIER
• 1.5. CHECKS AND ADJUSTMENTS
• 1.6. TROUBLESHOOTING
• 2. RM0432-(08-2004)-UK-EN
• 2.1. Safety Precautions Maintenance and Repair
• 2.2. General
• 2.3. Description and Operation
• 2.4. General
• 2.5. Lifting
• 2.6. High Speed
• 2.7. Normal Speed
• 2.8. Lowering
• 2.9. Safety Procedures When Working Near Mast
• 2.10. Forks Repair
• 2.11. Install
• 2.12. Low-Mount Fork
• 2.13. High-Mount Fork
• 2.14. Carriage Repair
• 2.15. Disassemble
• 2.16. Clean and Inspect
• 2.17. Assemble
• 2.18. Install
• 2.19. Mast Repair
• 2.20. Disassemble
• 2.21. Clean and Inspect
• 2.22. Assemble
• 2.23. Install
• 2.24. Lift Cylinders Repair
• 2.25. Disassemble
• 2.26. Clean and Inspect
• 2.27. Assemble
• 2.28. Install
• 2.29. Sideshift Cylinder Repair
• 2.30. Disassemble
• 2.31. Clean and Inspect
• 2.32. Assemble
• 2.33. Install
• 2.34. Fork Positioner Cylinders Repair
• 2.35. Disassemble
• 2.36. Clean and Inspect
• 2.37. Assemble
• 2.38. Install
• 2.39. Header Hoses Replacement
• 2.40. Carriage Side Rollers Adjustment
• 2.41. Mast Side Rollers Adjustment
• 2.42. Mast Load Rollers Adjustment
• 2.43. Lift Chains Adjustment
• 2.44. Lift and Tilt Cylinders Leak Check
• 2.45. Troubleshooting
• 2.46. Table 1. Weight of Components
• 2.47. Table 2. Hydraulic Line Codes
• 3. RM0626-(11-2001)-UK-EN
• 3.1. Cooling System
• 3.2. Safety Precautions Maintenance and Repair
• 3.3. General
• 3.4. Description
• 3.5. Radiator
• 3.6. Radiator Cap
• 3.7. Thermostat
• 3.8. Water Pump
• 3.9. Fan and Fan Shroud
• 3.10. Cooling System Checks
• 3.11. Radiator
• 3.12. Thermostat
• 3.13. Water Pump
• 3.14. Exhaust Leaks
• 3.15. Fan and Fan Shroud
• 3.16. Radiator Cleaning
• 3.17. Troubleshooting
• 4. RM0634-(03-2005)-UK-EN
• 4.1. Four-Speed Powershift Transmission
• 4.2. Safety Precautions Maintenance and Repair
• 4.3. General
• 4.4. Automatic Powershift Control
• 4.5. Transmission Control System
• 4.6. Transmission Control Lever
• 4.7. Mechanical Description and Operation
• 4.8. General
• 4.9. Torque Converter
• 4.10. Description
• 4.11. Operation
• 4.12. Clutch Assemblies
• 4.13. Description
• 4.14. Operation
• 4.15. Transmission Operation in Neutral
• 4.16. Input Shaft, Forward Shaft, and Clutch Assembly
• 4.17. Description
• 4.18. Operation
• 4.19. Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli
• 4.20. Description
• 4.21. Operation
• 4.22. Third-Speed Shaft, Gear, and Clutch Assembly
• 4.23. Description
• 4.24. Operation
• 4.25. Fourth-Speed Shaft and Clutch
• 4.26. Description
• 4.27. Operation
• 4.28. Output Shaft
• 4.29. Description
• 4.30. Operation
• 4.31. Hydraulic Description and Operation
• 4.32. Sump, Filter, and Pump
• 4.33. Transmission Charge Pump
• 4.34. Pressure Regulator Valve
• 4.35. Relief Valve
• 4.36. Transmission Control Valve
• 4.37. Solenoid Valves
• 4.38. Direction Spools
• 4.39. Range Spools
• 4.40. Modulator Valves
• 4.41. Table 1. Solenoid Controls
• 5. RM0635-(06-2007)-UK-EN
• 5.1. Four-Speed Powershift Transmission
• 5.2. Safety Precautions Maintenance and Repair
• 5.3. General
• 5.4. Torque Converter Repair
• 5.5. Torque Converter, Remove
• 5.6. Torque Converter, Disassemble
• 5.7. Clean and Inspect
• 5.8. Torque Converter, Assemble
• 5.9. Torque Converter (Turbine) Housing, Disassemble
• 5.10. Relief Valve for Lube Pressure, Disassemble and Assemble
• 5.11. Oil Sealing Rings Sleeve, Replace
• 5.12. Torque Converter Housing, Assemble
• 5.13. Torque Converter, Install
• 5.14. Transmission Repair
• 5.15. Remove, Transmission Only
• 5.16. Transmission and Engine Assembly, Remove
• 5.17. Transmission, Disassemble
• 5.18. Output Shaft, Disassemble and Assemble
• 5.19. Fourth-Speed Shaft, Disassemble and Assemble
• 5.20. Third-Speed Shaft, Disassemble and Assemble
• 5.21. Forward Shaft and Clutch, Disassemble and Assemble
• 5.22. Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem
• 5.23. First-Speed Shaft and Clutch, Disassemble and Assemble
• 5.24. Input Shaft, Disassemble and Assemble
• 5.25. Speed Sensor, Install
• 5.26. Transmission, Clean and Inspect
• 5.27. Transmission, Assemble
• 5.28. Control Valve
• 5.29. Clean and Inspect
• 5.30. Assemble and Install
• 5.31. Install, Transmission
• 5.32. Install, Transmission and Engine Assembly
• 5.33. Clean Oil System of Transmission After Major Repair
• 5.34. Automatic Powershift Control (APC 100)
• 5.35. Functional Description
• 5.36. Transmission Control Lever
• 5.37. First-Speed Shaft Bearings Adjustment
• 5.38. Torque Converter Stall Speed Check
• 5.39. Transmission Oil Pressures Check
• 5.40. Clutch Pressures Check
• 5.41. Torque Converter (Torque Converter Regulator) Oil Pressure Check
• 5.42. Troubleshooting
• 5.43. Transmission Controller (APC 100)
• 5.44. Table 1. Flange Nut Torque
• 5.45. Table 2. APC 100 Control Module (Pin Connections)
• 5.46. Table 3. Hobbs Gear Selector Connections
• 5.47. Table 4. Example Torque Values at Dimensions Shown
• 5.48. Table 5. Transmission Pressures
• 6. RM0071-(03-2006)-UK-EN
• 6.1. Steering Axle
• 6.2. Safety Precautions Maintenance and Repair
• 6.3. General
• 6.4. Description
• 6.5. Steering Axle Repair
• 6.6. Install
• 6.7. Steering Cylinder Repair
• 6.8. Inspect
• 6.9. Assemble
• 6.10. Install
• 6.11. H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B
• 6.12. H360-620B Models
• 6.13. H16.00-30.00C (H360-650C), H20.00-32.00F (H440-700F/FS), and H36
• 6.14. H36.00-48.00C (H800-1050C), H36.00-48.00E (H800-1050E), H20.00-3
• 6.15. Hubs Repair
• 6.16. H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), and P7.00-9
• 6.17. Install
• 6.18. H360-620B, H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C),
• 6.19. Install
• 6.20. Spindles Repair
• 6.21. Install
• 6.22. System Air Removal
• 6.23. Cylinder Stops Adjustment
• 6.24. Torque Specifications
• 6.25. H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B
• 6.26. H360-620B, H700-800A, H36.00-44.00B (H700-920B), H17.00-48.00C (
• 6.27. H360-620B, H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C)
• 6.28. H360-620B, H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C),
• 6.29. H360-620B
• 6.30. H700-800A, H36.00-44.00B (H700-920B)
• 6.31. H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C), H36.00-44.
• 6.32. H36.00-48.00E (H800-1050E), H36.00-48.00C (H800-1050C), H20.00-3
• 7. RM0046-(11-2014)-UK-EN
• 8. RM0097-(05-2012)-UK-EN
• 8.1. Hydraulic Gear Pumps
• 8.2. Safety Precautions Maintenance and Repair
• 8.3. Description
• 8.4. Operation
• 8.5. Flow Control Valve
• 8.6. Relief Valve
• 8.7. Hydraulic Gear Pump Repair
• 8.8. Disassemble
• 8.9. Inspect
• 8.10. Assemble
• 8.11. Install
• 8.12. Pump Output Check
• 8.13. Method No. 1
• 8.14. Method No. 2
• 8.15. Hydraulic System Air Check
• 8.16. Troubleshooting
• 9. RM0103-(03-2007)-UK-EN
• 9.1. Tilt Cylinders
• 9.2. Safety Precautions Maintenance and Repair
• 9.3. General
• 9.4. Description
• 9.5. Tilt Cylinder Repair
• 9.6. Disassemble
• 9.7. Assemble
• 9.8. Tilt Cylinders With O-Ring or Single-Lip Seals
• 9.9. Tilt Cylinders for XM and XMS Models
• 9.10. Tilt Cylinders for XL, XLS, and XL 3 Models
• 9.11. Tilt Cylinders for H700-800A and Early Model H700-920B
• 9.12. Install
• 9.13. Tilt Cylinders Using Chevron Packing
• 9.14. Tilt Cylinder Leak Check
• 9.15. Tilt Cylinder Stroke and Mast Tilt Angle Adjustment
• 9.16. Torque Specifications
• 9.17. Piston Rod Nut
• 9.18. Retainer
• 9.19. Troubleshooting
• 9.20. Table 1. Movement Rates (Maximum) for Tilt Cylinders
• 10. RM0143-(02-2007)-UK-EN
• 10.1. Instrument Panel Indicators and Senders
• 10.2. Safety Precautions Maintenance and Repair
• 10.3. General
• 10.4. Description
• 10.5. Steering Column Gauges, Meters, and Indicators
• 10.6. LED Display Panel
• 10.7. Battery Discharge Indicators
• 10.8. Brush Wear Indicators
• 10.9. Motor Temperature Indicators
• 10.10. LX Series Display Panel
• 10.11. Hourmeter Functions
• 10.12. Battery Indicator Function
• 10.13. Status Code Function
• 10.14. ZX Series Display Panels
• 10.15. Display Panel
• 10.16. Basic Display Panels
• 10.17. Performance Display
• 10.18. Brush Wear Indicators
• 10.19. Adjustments – General
• 10.20. Replacement – General Information
• 10.21. Meter Replacement
• 10.22. Sender Replacement
• 10.23. Fuel Level Sender
• 10.24. Pressure and Temperature Sender
• 10.25. Seat Sensor, Operator Presence System (OPS)
• 10.26. Install
• 10.27. Operator Presence System Module Replacement
• 10.28. Install
• 10.29. ITW Display Panel Replacement
• 10.30. Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl
• 10.31. Display Panel Assembly, Replace
• 10.32. Indicator LEDs
• 10.33. Battery Indicators
• 10.34. Digital Display (Performance Display Panel Only)
• 10.35. Status Code or Performance Level Switches and Indicator LEDs (Pe
• 10.36. Basic Display Panel, Replace Parts
• 10.37. Performance Display Panel, Replace Parts
• 10.38. Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace
• 10.39. Remove and Replace
• 10.40. Specifications
• 10.41. Meter Specifications
• 10.42. Sender Specifications
• 10.43. Troubleshooting
• 10.44. Troubleshooting for Operator Presence System
• 10.45. Table 1. Troubleshooting Procedure for Operator Presence Module
• 11. RM0144-(05-1997)-UK-EN
• 11.1. ELECTRICAL WARNING DEVICES
• 12. RM0231-(01-2016)-UK-EN
• 12.1. General
• 13. RM0265-(11-1997)-UK-EN
• 13.1. INTRODUCTION
• 13.2. REPAIRS
• 13.3. CHECKS AND ADJUSTMENTS
• 13.4. TROUBLESHOOTING
• 14. RM0266-(11-1997)-UK-EN
• 14.1. INTRODUCTION
• 14.2. REPAIRS
• 14.3. CHECKS AND ADJUSTMENTS
• 14.4. TROUBLESHOOTING
• 15. RM0676-(09-2006)-UK-EN
• 15.1. Diagrams
• 15.2. Safety Precautions Maintenance and Repair
• 16. RM0677-(01-2005)-UK-EN
• 16.1. Periodic Maintenance
• 16.2. Safety Precautions Maintenance and Repair
• 16.3. General
• 16.4. Serial Number Data
• 16.5. How to Move Disabled Lift Truck
• 16.6. How to Tow Lift Truck
• 16.7. How to Put Lift Truck on Blocks
• 16.8. How to Raise Drive Tires
• 16.9. How to Raise Steering Tires
• 16.10. Maintenance Schedule
• 16.11. Spreader Maintenance
• 16.12. Maintenance Procedures Every 8 Hours or Daily
• 16.13. How to Make Checks With Engine Stopped
• 16.14. Safety Labels
• 16.15. Operator Restraint System
• 16.16. Steering Column Latch
• 16.17. Tires and Wheels
• 16.18. Forks, Mast, and Lift Chains, Inspect
• 16.19. Drive Belt
• 16.20. Crankcase Breather Tube
• 16.21. Air Intake Piping and Charge Air Piping
• 16.22. Cooling Fan
• 16.23. Precleaner for Air Filter
• 16.24. Air Filter
• 16.25. Fuel, Oil, or Coolant Leak Check
• 16.26. Engine Oil
• 16.27. Hydraulic System Oil
• 16.28. Hydraulic Oil Filters
• 16.29. Hydraulic Filter
• 16.30. Battery
• 16.31. Splash Fuses
• 16.32. Cooling System
• 16.33. Fuel Filter/Water Separator
• 16.34. How to Make Checks With Engine Running
• 16.35. Engine Fault Codes
• 16.36. Gauges, Lights, Horn, Fuses, and Relays
• 16.37. Engine Oil Pressure
• 16.38. Electrical System
• 16.39. Transmission Oil
• 16.40. Steering System
• 16.41. Service Brakes
• 16.42. Parking Brake
• 16.43. Fuel System
• 16.44. Primary Fuel Filter
• 16.45. Control Levers and Pedals
• 16.46. Lift System Operation
• 16.47. Attachments
• 16.48. How to Add Fuel to Lift Truck
• 16.49. Maintenance Procedures Every 250 Hours Or Monthly
• 16.50. Twist Locks
• 16.51. Gantry Carriage and Container Attachments
• 16.52. Maintenance Procedures Every 500 Hours or 3 Months
• 16.53. Drive Belt
• 16.54. Lift Chains
• 16.55. Hydraulic Return Line Oil Filter
• 16.56. Air Conditioning
• 16.57. Wheel Nuts
• 16.58. Heater Air Filter
• 16.59. Steering Axle Kingpins
• 16.60. Steering Axle Tie Rods
• 16.61. Drive Shaft
• 16.62. Steering Axle Pivots
• 16.63. Mast and Carriage Load Rollers
• 16.64. Mast Pivots, Sliding Surfaces
• 16.65. Sideshift Carriage
• 16.66. Maintenance Procedures Every 500 Hours or 6 Months
• 16.67. Fuel Filter
• 16.68. Engine Oil and Filter
• 16.69. Oil Filter for Oil Cooled Brakes (Brake Filter)
• 16.70. Change Transmission Oil
• 16.71. Maintenance Procedures Every 1000 Hours or 6 Months
• 16.72. Drive Axle and Differential Oil
• 16.73. Service Brake System
• 16.74. Brake System Accumulator
• 16.75. Hub Bearings, Steer Wheels
• 16.76. General Lubrication
• 16.77. Maintenance Procedures Every 1500 Hours or 1 Year
• 16.78. Water Pump