Hyster H117 (H1050HD-16CH, H1150HD-16CH) Forklift Parts Manual

H1050HD-16CH, H1150HD-16CH (H117)

4114872 01/2016

©2015 HYSTER COMPANY

UNIT CODE H117 NORTH AMERICA

01/2016

SECTIONS 1

FRAME

2

ENGINE ASSEMBLY

3

FUEL SYSTEM

4

ELECTRICAL SYSTEM

5

TRANSMISSION

6

DRIVE AXLE

7

STEERING SYSTEM

8

BRAKE SYSTEM

9

HYDRAULIC SYSTEM

10

MAST WITH CONTAINER HANDLER

11

ATTACHMENTS

12

OPTIONS

13

FIELD CONVERSION KITS

14

NUMERICAL INDEX

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01/2016

UNIT CODE H117 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

A ACCESSORY DRIVE PULLEY TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

AIR CLEANER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

AIR COMPRESSOR AND HOSES TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE (→ S/N H117E01527N) ..............................................................................................

TIER 4(F) ENGINE (S/N H117E01528N →) ..............................................................................................

AIR CONDITIONER CLIMATE CONTROL CAB ..........................................................................................................................

AIR CONDITIONER ASSEMBLY CAB WITH AIRCO ......................................................................................................................................

AIR CONDITIONER SYSTEM CLIMATE CONTROL CAB ..........................................................................................................................

AIR CONDITIONER SYSTEM ASSEMBLY CAB WITH AIRCO ......................................................................................................................................

AIR DUCT CLOSED CAB WITH AIRCO OR CLIMATE CONTROL .............................................................................

AIR DUCT ASSEMBLY AIR CONDITIONING - CAB WITH AIRCO OR WITH CLIMATE CONTROL ..............................................

HEATER ......................................................................................................................................................

AIR HORN .......................................................................................................................................................

AIR INTAKE CONNECTION TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

AIR INTAKE HOSE TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

AIR INTAKE MANIFOLD TIER 3 ENGINE ..........................................................................................................................................

AIR INTAKE SYSTEM TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

AIR TRANSFER CONNECTION TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

AIRFLOW SCREEN CABIN TOWER ...........................................................................................................................................

ALTERNATOR TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

ALTERNATOR DRIVE PULLEY TIER 3 ENGINE ..........................................................................................................................................

ALTERNATOR MOUNTING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

ARMREST ASSEMBLY ...................................................................................................................................

AUTOMATIC GREASING PUMP ....................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-27 2-28 2-29 1-38 1-39 1-40 1-70 1-64 1-68 1-56 12-2 1-62 1-50 1-46 3-5 3-6 3-4 3-8 3-2 3-3 3-7 2-30 1-14 4-111 4-115 4-112 4-114 1-72 9-56

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

AUTOMATIC GREASING SYSTEM PAGE 1 OF 3 ..............................................................................................................................................

PAGE 2 OF 3 ..............................................................................................................................................

PAGE 3 OF 3 ..............................................................................................................................................

AUXILIARY COOLING PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

B BATTERY BOX COVER ..................................................................................................................................

BELT TENSIONER TIER 4(F) ENGINE ......................................................................................................................................

BLOCK ASSEMBLY AND HOSES, TWIN 12-PORT WITH METERING UNIT NUMBERS 3, 8, AND 10 - STEER AXLE LUBRICATION ...................................

BLOCK ASSEMBLY AND HOSES, TWIN 7-PORT WITH METERING UNIT NUMBERS 4 AND 8 - MAST MOUNTING LUBRICATION .................................

BRAKE ACCUMULATOR AND MOUNTING HARDWARE ............................................................................

BRAKE MANIFOLD AND ATTACHING BRAKE HOSES ................................................................................

BRAKE PEDAL AND LINKAGE ......................................................................................................................

BRAKE PEDAL ASSEMBLY ...........................................................................................................................

BRAKE VALVE AND ATTACHING BRAKE HOSES .......................................................................................

BREATHER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

BUMPERS .......................................................................................................................................................

C CAB ATTACHING PARTS PAGE 1 OF 3 ..............................................................................................................................................

PAGE 2 OF 3 ..............................................................................................................................................

PAGE 3 OF 3 ..............................................................................................................................................

CAB DOOR LEFT HAND ................................................................................................................................................

RIGHT HAND ..............................................................................................................................................

CAB FLOORMATS ..........................................................................................................................................

CAB MAIN DOOR WINDOW RIGHT AND LEFT HAND ............................................................................................................................

CAB MOUNTING AND HOSE SUPPORT ......................................................................................................

CAB RECIRCULATING FAN ...........................................................................................................................

CAB SUNSHADE REAR ..........................................................................................................................................................

TOP .............................................................................................................................................................

CAB WINDOWS INSTALLATION ...................................................................................................................

CABIN HEATER PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

CAM FOLLOWER LEVERS TIER 3 ENGINE ..........................................................................................................................................

CAMSHAFT TIER 3 ENGINE ..........................................................................................................................................

CLIMATE CONTROL SYSTEM .......................................................................................................................

ii

See Service Manual for service procedures.

9-46 9-48 9-50 2-31 1-10 2-32 9-54 9-52 8-8 8-9 8-6 8-4 8-2 2-33 2-34 11-6

1-86 1-88 1-90 1-82 1-84 1-76 1-91 1-16 12-4 12-6 12-5 1-80 2-35 2-36 2-38 1-66

©2015 HYSTER COMPANY

01/2016

UNIT CODE H117 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

COMPRESSOR ASSEMBLY TIER 4(F) ENGINE ......................................................................................................................................

COMPRESSOR MOUNTING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

CONDENSER CAB WITH AIRCO OR WITH CLIMATE CONTROL ...................................................................................

CONDENSER SYSTEM CAB WITH AIRCO OR WITH CLIMATE CONTROL ...................................................................................

CONTROL PANEL ASSEMBLY HEATER ......................................................................................................................................................

HEATER AND AIR CONDITIONER ............................................................................................................

CONTROL VALVE ASSEMBLY AUXILIARY ..................................................................................................................................................

CAP AND SUPPORT KIT ...........................................................................................................................

LIFT .............................................................................................................................................................

LIFT AND TILT ............................................................................................................................................

CONTROLLER SEAT BELT SEQUENCER .........................................................................................................................

COOLANT HEATER STARTING AID TIER 3 ENGINE ..........................................................................................................................................

COOLER AND ATTACHING BRAKE HOSES ................................................................................................

COOLER ASSEMBLY .....................................................................................................................................

COOLING SYSTEM TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

CORROSION RESISTOR TIER 3 ENGINE ..........................................................................................................................................

COUNTERWEIGHT ........................................................................................................................................

CRANKSHAFT TIER 3 ENGINE ..........................................................................................................................................

CRANKSHAFT MAIN BEARINGS TIER 3 ENGINE ..........................................................................................................................................

CYLINDER POWER PILE SLOPE .................................................................................................................................

CYLINDER BLOCK TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

CYLINDER BLOCK PLUMBING TIER 3 ENGINE ..........................................................................................................................................

CYLINDER HEAD TIER 3 ENGINE ..........................................................................................................................................

D DASH ASSEMBLY ..........................................................................................................................................

DC-DC CONVERTER AND ATTACHING PARTS ..........................................................................................

DEF SUPPLY MODULE ..................................................................................................................................

DEF SYSTEM TIER 4(F) ENGINE ......................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-42 2-40 2-42 1-60 1-58 4-109 4-110 9-32 9-38 9-34 9-36 12-8 2-43 8-14 2-10 2-6 2-8 2-44 1-15 2-46 2-47 11-5 2-48 2-52 2-50 2-54 1-78 12-9 3-37 3-34

iii

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

DIFFERENTIAL AND CARRIER ASSEMBLY .................................................................................................

DRIVE AXLE AND ATTACHING BRAKE HOSES ..........................................................................................

DRIVE SHAFT .................................................................................................................................................

DRIVE WHEELS AND TIRES 18.00 X 25 (→ S/N H117E01529N) ...........................................................................................................

18.00 X 25 (S/N H117E01530N →) ...........................................................................................................

18.00 X 33 ...................................................................................................................................................

E ELECTRICAL SYSTEM TIER 3 ENGINE - PAGE 1 OF 2 (→ PENDING PER ECN 68671-27) .......................................................

TIER 3 ENGINE - PAGE 1 OF 2 (PENDING PER ECN 68671-27 →) .......................................................

TIER 3 ENGINE - PAGE 2 OF 2 .................................................................................................................

TIER 4(F) ENGINE - PAGE 1 OF 2 (→ PENDING PER ECN 68671-27) ..................................................

TIER 4(F) ENGINE - PAGE 1 OF 2 (PENDING PER ECN 68671-27 →) ..................................................

TIER 4(F) ENGINE - PAGE 2 OF 2 .............................................................................................................

EMPTY SEAT ENGINE SHUTDOWN .............................................................................................................

ENGINE BLOCK HEATER 240V .....................................................................................................................

ENGINE CONTROL MODULE TIER 4(F) ENGINE ......................................................................................................................................

ENGINE CONTROL SYSTEM TIER 3 ENGINE ..........................................................................................................................................

ENGINE COOLANT PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

ENGINE COVERS ...........................................................................................................................................

ENGINE MOUNTING AND CHARGE AIR COOLER TUBES TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

ENGINE OIL FILL TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

ENGINE SUPPORT TIER 4(F) ENGINE ......................................................................................................................................

ETR CONTROL MODULE WIRE HARNESS TIER 4(F) ENGINE ......................................................................................................................................

EXHAUST MANIFOLD TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

EXHAUST OUTLET CONNECTION TIER 3 ENGINE ..........................................................................................................................................

EXHAUST PIPE DRT - TIER 4(F) ENGINE ...........................................................................................................................

EXHAUST RECIRCULATION TIER 4(F) ENGINE ......................................................................................................................................

EXHAUST RECIRCULATION AIR PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

EXHAUST RECIRCULATION WATER PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

iv

See Service Manual for service procedures.

6-2 8-16 5-44 6-12 6-14 6-16

4-4 4-6 4-8 4-12 4-14 4-16 12-10 12-11 4-116 4-122 2-56 1-12 2-24 2-26 2-58 2-60 2-61 4-118 2-62 2-63 2-64 2-20 2-65 2-67 2-66

©2015 HYSTER COMPANY

01/2016

UNIT CODE H117 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

EXHAUST SYSTEM TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

EXPANSION TANK AND HOSES TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

F FAN DRIVE AND MOUNTING TIER 4(F) ENGINE ......................................................................................................................................

FAN DRIVE AND SPACER TIER 3 ENGINE ..........................................................................................................................................

FLOORPLATES, STEPS, AND RAILS PAGE 1 OF 2 ..............................................................................................................................................

PAGE 2 OF 2 ..............................................................................................................................................

FLOW AMPLIFIER AND ATTACHING HYDRAULIC HOSES ........................................................................

FLYWHEEL TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

FLYWHEEL HOUSING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

FRONT DRIVE TRAIN TIER 3 ENGINE ..........................................................................................................................................

FRONT ENGINE SUPPORT TIER 3 ENGINE ..........................................................................................................................................

FRONT GEAR COVER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

FRONT GEAR TRAIN ACCESSORY MOUNTING TIER 4(F) ENGINE ......................................................................................................................................

FUEL DRAIN PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

FUEL FILTER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

FUEL FILTER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

FUEL PUMP ASSEMBLY TIER 3 ENGINE ..........................................................................................................................................

FUEL PUMP COUPLING TIER 3 ENGINE ..........................................................................................................................................

FUEL PUMP DRIVE TIER 3 ENGINE ..........................................................................................................................................

FUEL PUMP INTAKE FITTING TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

FUEL PUMP PLUMBING TIER 3 ENGINE ..........................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-16 2-18 2-12 2-14

2-68 2-69 1-4 1-6 9-14 2-73 2-74 2-70 2-72 2-75 2-76 2-78 2-80 2-81 3-18 3-20 3-22 3-24 3-26 3-10 3-13 3-14 3-15 3-16

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

FUEL SUPPLY PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

FUEL SYSTEM TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

FUEL TANK .....................................................................................................................................................

FUEL TRANSFER PUMP TIER 4(F) ENGINE ......................................................................................................................................

3-30 3-32 3-33 3-31 3-28

G GEAR HOUSING TIER 3 ENGINE .......................................................................................................................................... 2-82 TIER 4(F) ENGINE ...................................................................................................................................... 2-83 H HEADER HOSES ............................................................................................................................................

HEAT SHIELD TIER 4(F) ENGINE ......................................................................................................................................

HEATED TOP WINDOW .................................................................................................................................

HEATER AND AIR DUCT ...............................................................................................................................

HEATER AND CONTROL PANEL ASSEMBLIES ..........................................................................................

HEATER ASSEMBLY ......................................................................................................................................

HEATER HOSES TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

HIGH PRESSURE HYDRAULIC FILTER AND ATTACHING BRAKE HOSES ..............................................

HUB ASSEMBLY .............................................................................................................................................

HYDRAULIC CONTROLS JOYSTICK ...................................................................................................................................................

HYDRAULIC GEAR PUMP FIXED DISPLACEMENT .............................................................................................................................

HYDRAULIC PUMP AND ATTACHING BRAKE HOSES ...............................................................................

HYDRAULIC PUMPS ......................................................................................................................................

HYDRAULIC TANK .........................................................................................................................................

HYDRAULIC TANK AND ATTACHING BRAKE HOSES ................................................................................

HYDRAULIC TANK AND ATTACHING HYDRAULIC HOSES .......................................................................

I IDLER GEAR TIER 3 ENGINE ..........................................................................................................................................

INDICATOR DISPLAY AND CONTROLS .......................................................................................................

INSULATION MATS AND AIR DUCT CLIMATE CONTROL CAB ..........................................................................................................................

INTAKE CONNECTOR AIR COMPRESSOR - TIER 3 ENGINE ......................................................................................................

INTAKE MANIFOLD TIER 4(F) ENGINE ......................................................................................................................................

11-2 2-84 12-12 1-48 1-52 1-54 1-43 1-44 8-12 6-4 9-28 9-10 8-13 9-6 9-4 8-15 9-2

2-86 4-22 12-14 2-88 2-89

J JOYSTICK ASSEMBLY ................................................................................................................................... 9-30 vi

See Service Manual for service procedures.

©2015 HYSTER COMPANY

01/2016

UNIT CODE H117 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

L LABELS PAGE 1 OF 3 ..............................................................................................................................................

PAGE 2 OF 3 ..............................................................................................................................................

PAGE 3 OF 3 ..............................................................................................................................................

LIFT ACCUMULATOR AND ATTACHING PARTS .........................................................................................

LIFT CYLINDER 12650 MM (498.0 IN.) LIFT HEIGHT ..........................................................................................................

7010 MM (275.9 IN.), AND 9754 MM (384.0 IN.) LIFT HEIGHT .................................................................

LIFT/TILT MANIFOLD AND ATTACHING HYDRAULIC HOSES ...................................................................

LIFTING BRACKET TIER 3 ENGINE ..........................................................................................................................................

LIFTING BRACKETS TIER 4(F) ENGINE ......................................................................................................................................

LIGHT BAR AND MOUNT TWISTLOCK MODULE ...............................................................................................................................

TWISTLOCK MODULE - ALTERNATE CONFIGURATION .......................................................................

LIGHT SWITCHES ..........................................................................................................................................

LIGHTS CAB WORK - HALOGEN ............................................................................................................................

CAB WORK - HID .......................................................................................................................................

ENGINE COMPARTMENT .........................................................................................................................

FENDER AND TAIL ....................................................................................................................................

STROBE ASSEMBLY - WITH CONDENSER .............................................................................................

STROBE ASSEMBLY - WITHOUT CONDENSER .....................................................................................

M MAIN HYDRAULIC CONTROL VALVE AND ATTACHING HYDRAULIC HOSES .........................................

MAIN MANIFOLD AND ATTACHING BRAKE HOSES ...................................................................................

MAIN MANIFOLD AND ATTACHING HYDRAULIC HOSES ..........................................................................

MAIN MANIFOLD ASSEMBLY PAGE 1 OF 2 ..............................................................................................................................................

PAGE 2 OF 2 ..............................................................................................................................................

MANIFOLD LIFT AND TILT ............................................................................................................................................

MAP READING LIGHT ....................................................................................................................................

MAST ASSEMBLY WITH GANTRY CARRIAGE .......................................................................................................................

MAST INSTALLATION ....................................................................................................................................

MIRRORS FRONT FENDER ........................................................................................................................................

MUFFLER/CATALYTIC CONVERTER ASSEMBLY DOC - TIER 4(F) ENGINE ...........................................................................................................................

SCR - TIER 4(F) ENGINE ...........................................................................................................................

1-96 1-98 1-100 9-43 10-8 10-6 9-8 2-90 2-91 1-92 1-94 4-96 4-102 4-104 4-97 4-100 4-98 4-99 9-40 8-11 9-12 9-16 9-18 9-44 12-16 10-2 10-10 1-45 2-22 2-21

O OIL COOLER TIER 4(F) ENGINE ...................................................................................................................................... 2-93

©2015 HYSTER COMPANY

See Service Manual for service procedures.

vii

UNIT CODE H117 NORTH AMERICA

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

OIL COOLER AND FILTER HEAD ADAPTER TIER 3 ENGINE ..........................................................................................................................................

OIL COOLER WATER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

OIL FILLER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

OIL FILTER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

OIL LEVEL GAUGE TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

OIL PAN TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

OIL PUMP AND ATTACHING PARTS TIER 3 ENGINE ..........................................................................................................................................

P PARK BRAKE ASSEMBLY .............................................................................................................................

PARK BRAKE RETAINER ..............................................................................................................................

PEDAL LINKAGE FORWARD/REVERSE LEVER ...................................................................................................................

PIVOT ARM ASSEMBLY ................................................................................................................................

PLUG, COOLANT HEATER STARTING AID TIER 4(F) ENGINE ......................................................................................................................................

PROXIMITY SWITCH ......................................................................................................................................

R RADIATOR PLUMBING TIER 3 ENGINE ..........................................................................................................................................

RADIO CONSOLE AND ATTACHING PARTS ...............................................................................................

REAR LOCKING CONSOLE ...........................................................................................................................

RELAYS AND FUSES .....................................................................................................................................

REMOTE OIL FILTER, HOSES, AND ATTACHING PARTS TIER 4(F) ENGINE ......................................................................................................................................

S SEAT ASSEMBLY SUSPENSION .............................................................................................................................................

SEAT ASSEMBLY, AIR SUSPENSION ..........................................................................................................

DELUXE ......................................................................................................................................................

WITH THREE POINT SEAT BELT ..............................................................................................................

SEAT ASSEMBLY, MECHANICAL SUSPENSION .........................................................................................

SECOND 12V SOCKET OPTION ONLY WITH DC-DC CONVERTER ............................................................................................................

SERVICE BRAKE ASSEMBLY .......................................................................................................................

SPEED LIMITING GANTRY CARRIAGE .................................................................................................................................. viii

See Service Manual for service procedures.

2-102 2-92 2-97 2-98 2-99 2-100 2-95 2-96 2-104 2-106 2-108 6-10 6-8 3-40 1-74 2-109 4-108

2-110 12-18 12-20 4-42 2-23

1-30 1-20 1-22 1-24 1-18 12-21 6-6 4-106

©2015 HYSTER COMPANY

01/2016

UNIT CODE H117 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

START AID ......................................................................................................................................................

STARTER TIER 4(F) ENGINE ......................................................................................................................................

STARTER MOTOR AND MOUNTING TIER 3 ENGINE ..........................................................................................................................................

STEER AXLE AND ATTACHING PARTS .......................................................................................................

STEER AXLE ASSEMBLY PAGE 1 OF 2 ..............................................................................................................................................

PAGE 2 OF 2 ..............................................................................................................................................

STEER COLUMN ASSEMBLY ........................................................................................................................

ALTERNATE CONFIGURATION ................................................................................................................

STEER CYLINDER .........................................................................................................................................

STEER TIRES AND WHEELS 18.00 X 25 (→ S/N H117E01529N) ...........................................................................................................

18.00 X 25 (S/N H117E01530N →) ...........................................................................................................

18.00 X 33 ...................................................................................................................................................

STEER VALVE AND ATTACHING HYDRAULIC HOSES ..............................................................................

STEERING COLUMN ......................................................................................................................................

STEERING CONTROL UNIT ..........................................................................................................................

STEERING CONTROL VALVE .......................................................................................................................

STEERING HOSES .........................................................................................................................................

SUSPENSION KIT ASSEMBLY ......................................................................................................................

12-22

T TELEMETRY KITS ..........................................................................................................................................

THERMOSTAT TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

THERMOSTAT HOUSING TIER 3 ENGINE ..........................................................................................................................................

THROTTLE AND INCHING SENSORS ..........................................................................................................

TILT CYLINDER ASSEMBLY ..........................................................................................................................

TILT CYLINDERS AND ATTACHING PARTS ................................................................................................

TILT HYDRAULICS .........................................................................................................................................

TRAINING SEAT .............................................................................................................................................

TRANSMISSION CASE AND REAR COVER .........................................................................................................................

CONTROL VALVE ......................................................................................................................................

FIRST SPEED CLUTCH SHAFT ................................................................................................................

FIRST SPEED GEARS ...............................................................................................................................

FIRST SPEED SHAFT AND IDLER GEAR .................................................................................................

FORWARD CLUTCH SHAFT .....................................................................................................................

FORWARD, REVERSE AND SECOND, - AND THIRD OR FOURTH CLUTCH SHAFTS .........................

FOURTH SPEED CLUTCH SHAFT ............................................................................................................

INPUT DRIVE GEARS ................................................................................................................................

OUTPUT SHAFT .........................................................................................................................................

PUMP DRIVE ..............................................................................................................................................

REGULATOR VALVE AND HYDRAULIC PUMP ........................................................................................

REMOTE FILTER AND ADAPTER .............................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

4-119 4-120 7-2 7-22 7-24 7-12 7-14 7-4 7-18 7-20 7-21 9-20 7-16 7-8 7-10 7-6 1-28 13-2 2-112 2-113 2-114 3-38 9-24 9-22 9-26 12-23 5-10 5-42 5-30 5-21 5-34 5-22 5-20 5-32 5-14 5-36 5-16 5-38 5-40

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PAGE

REVERSE AND SECOND CLUTCH SHAFT ..............................................................................................

THIRD SPEED CLUTCH SHAFT ................................................................................................................

THIRD SPEED GEARS ...............................................................................................................................

TORQUE CONVERTER AND DRIVE PLATE ............................................................................................

TORQUE CONVERTER HOUSING ............................................................................................................

TURBINE SHAFT, STATOR SUPPORT, OIL BAFFLE ..............................................................................

TRANSMISSION CONTROL ...........................................................................................................................

TRANSMISSION LINES AND ATTACHING PARTS ......................................................................................

TRANSMISSION MOUNTING .........................................................................................................................

TURBOCHARGER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

TURBOCHARGER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

TURBOCHARGER WATER PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

V VALVE COVER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

VIBRATION DAMPER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

W WATER PUMP TIER 3 ENGINE ..........................................................................................................................................

WATER PUMP AND CONNECTIONS TIER 4(F) ENGINE ......................................................................................................................................

WINDOW WIPER SYSTEM REAR AND ROOF WIPER KITS - AND FRONT WIPER OPTIONS ..........................................................

WASHER BOTTLE KIT ...............................................................................................................................

WIRE HARNESS ARMREST ...................................................................................................................................................

BACK-UP ALARM .......................................................................................................................................

CAB LIGHTS ...............................................................................................................................................

CAB SIDE CONSOLE - PAGE 1 OF 3 ........................................................................................................

CAB SIDE CONSOLE - PAGE 2 OF 3 ........................................................................................................

CAB SIDE CONSOLE - PAGE 3 OF 3 ........................................................................................................

CAB UNDERFLOOR ...................................................................................................................................

CHASSIS - PAGE 1 OF 2 (→ S/N H117E01503M) ...................................................................................

CHASSIS - PAGE 1 OF 2 (S/N H117E01505M →) ...................................................................................

CHASSIS - PAGE 2 OF 2 ...........................................................................................................................

CLOSED CAB .............................................................................................................................................

COOLANT LEVEL SWITCH - TIER 4(F) ENGINE ......................................................................................

COOLANT LEVEL SWITCH - TIER 3 ENGINE ..........................................................................................

ECO/ELO-HIP .............................................................................................................................................

ENGINE AFTERTREATMENT SYSTEM/ECM - TIER 4(F) ENGINE .........................................................

x

See Service Manual for service procedures.

5-28 5-24 5-26 5-18 5-6 5-12 4-20 5-2 5-4 2-116 2-118 2-120 2-122

2-124 2-126 2-128 2-129

2-130 2-132 1-36 1-34 4-24 4-27 4-28 4-30 4-34 4-38 4-46 4-50 4-54 4-58 4-61 4-64 4-65 4-69 4-66

©2015 HYSTER COMPANY

01/2016

UNIT CODE H117 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

ENGINE ECM ADAPTER - TIER 3 ENGINE ..............................................................................................

FRONT LIGHTS ..........................................................................................................................................

MANIFOLD ..................................................................................................................................................

MAST ..........................................................................................................................................................

PDM ............................................................................................................................................................

POWERTRAIN - FULL FLOW .....................................................................................................................

PRESSURE SWITCH BASE .......................................................................................................................

PROXIMITY SWITCH - GANTRY ...............................................................................................................

PROXIMITY SWITCH - LIFT AND TILT ......................................................................................................

PUMP BASE TRUCK ..................................................................................................................................

REAR ..........................................................................................................................................................

REAR WIPER EXTENSION ........................................................................................................................

STEER COLUMN ........................................................................................................................................

TWIN FRONT FENDER WORK LIGHTS ....................................................................................................

WIF SENSOR ..............................................................................................................................................

WINDOW WASH PUMPS ...........................................................................................................................

WIRE MESH ROOF PROTECTION ................................................................................................................

WIRING ACCESSORIES ELECTRONIC CONTROL MODULE - TIER 3 ENGINE .............................................................................

4-70 4-72 4-74 4-76 4-78 4-82 4-86 4-87 4-88 4-89 4-90 4-91 4-92 4-93 4-94 4-95 12-24

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: spacer TERM

DEFINITION

TERM

DEFINITION

Amp

Amperes

FRE

Freezer Environment

AR

As Required

in.

inches

BDI

Battery Discharge Indicators

LPG

Liquefied Petroleum Gas

BWI

Brush Wear Indicator

MAP

Manifold Absolute Pressure

CE

Communicator End

mm

millimeters

CRE

Corrosive Environment

MSTS

Microprocessor Spark Timing System

D/B

Date Break

NPT

National Pipe Threads

dbA

Decibel "A" Scale

O/S

Oversize

DE

Drive End

PTO

Power Take Off

ECH

Empty Container Handler

RPM

Revolutions per Minute

ECH-3

Empty Container Handler - 3 High Stacking

S/N

Serial Number

TMM

Truck Management Module

ECH-4

Empty Container Handler - 4 High Stacking

UL Type D

Diesel-Powered Safety Rating

ECH-5

Empty Container Handler - 5 High Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

ECH-6

Empty Container Handler - 6 High Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High Stacking

UL Type G

Gasoline-Powered Safety Rating

UL Type GS

Gasoline-Powered Safety Rating

ECM

Electronic Control Module

UL Type LP

Gas-Powered Safety Rating

ECN

Engineering Change Notice

UL Type LPS

LP Gas-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

U/S

Undersize

EPA

US Environmental Protection Agency

UL

Underwriters Laboratory

EPROM

Electrically Programmable Read Only Memory

V

Volts

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See Service Manual for service procedures.

©2015 HYSTER COMPANY

01/2016

UNIT CODE H117 NORTH AMERICA

HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

©2015 HYSTER COMPANY

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

See Service Manual for service procedures.

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HOW TO FIND THE DESIRED PART NUMBER

1.

2.

3.

4.

5.

WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).

Locate the assembly the required part is used on and turn to the page indicated for that assembly.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN: Use the Numerical Index (Page 14-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL:

6.

The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

Parts Supersession Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.

Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure.

A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (FFigure 10)

7.

8.

xiv

Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc.

Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

Indented descriptions under the DESCRIPTION column are used to indicate assemblies and

subparts of assemblies. In the example on the previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE. 9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

10. Serial number breaks identify the most current parts information and are shown as follows: → S/N D001H2628 Indicates last serial number affected.

S/N D001H2629 → Indicates the first serial number affected.

S/N D001H1553 ↔ S/N D001H3291 Indicates a range of serial numbers affected.

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows: → S/N Pending Per ECN 63243 Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 → Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows: → D/B 3/00 Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 → Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ↔ D/B 4/00 Indicates a range of production dates of the item affected.

Contact your local dealer for Hyster lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS: When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Hyster lift trucks.

See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE H117 NORTH AMERICA

01/2016

IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2)

The first letter and three numbers indicate the truck unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number of the truck.

(5)

The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.

The letters "I", "O", and "Q" will not be used.

For pending serial numbers contact your local dealer for Hyster lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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