Hyster D117 (H36.00-48.00E, H36.00-H48.00E-16CH) Forklift Parts Manual

10/2005 UNIT CODE D117 EUROPE SECTIONS 1 FRAME 2 ENGINES 3 FUEL SYSTEM 4 ELECTRICAL SYSTEM 5 TRANSMISSION 6 DRIVE AXLE 7 STEERING SYSTEM 8 BRAKE SYSTEM 9 HYDRAULIC SYSTEM 10 MAST-TWO STAGE LIMITED FREE-LIFT 11 ATTACHMENTS 12 OPTIONS 13 NUMERICAL INDEX This Parts Manual is divided into 13 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

10/2005 UNIT CODE D117 EUROPE TABLE OF CONTENTS DESCRIPTION PAGE A ACCESSORY DRIVE PULLEY TIER I ENGINE ............................................................................................................................................. 2-104 ACCUMULATOR ATTACHING PARTS........................................................................................................................................ 9-28 PISTON TYPE ................................................................................................................................................ 9-30 ACCUMULATOR CHARGE VALVE .................................................................................................................... 9-26 ATTACHING PARTS ⇒S/N D117E-1681...................................................................................................................................... 9-24 AIR FILTER ⇒S/N D117E-1581 ....................................................................................................................................... 2-130 AIR FILTER SYSTEM ⇒S/N D117E-1581 ....................................................................................................................................... 2-132 S/N D117E-1582⇒ ....................................................................................................................................... 2-134 AIR INLET CONNECTION TIER II ENGINE ⇒S/N D117E01774Z (216 KW), ⇒S/N D117E01811A (246 KW) .............................................................. 2-54 AIR INTAKE CONNECTION TIER II ENGINE .............................................................................................................................................. 2-64 AIR OUTLET CONNECTION TIER II ENGINE .............................................................................................................................................. 2-66 AIR TRANSFER CONNECTION TIER II ENGINE .............................................................................................................................................. 2-68 ALTERNATOR AND MOUNTING ..................................................................................................................... 4-114 ANTI-SLACK DEVICE S/N D117E-1631⇔S/N D117E-1681 .............................................................................................................. 9-90 ANTI-SLACK DEVICE AND LIFT INTERRUPT S/N D117E-1631⇔S/N D117E-1681 .............................................................................................................. 9-92 AXLE HOUSING S/N D117E01800A⇒ INC. 1796 (WIDE), S/N D117E01805A⇒ INC. 1797 (NARROW) ............................... 6-26 B BLOCK VALVE ATTACHING PARTS EXTENDABLE ATTACHMENT WITH DEDICATED CARRIAGE ⇒S/N D117E-1633 ................................................................................................................................ 11-54 BRAKE LINES CONTROL ...................................................................................................................................................... 8-12 DISC BRAKE DRY BRAKE ⇒S/N D117E-01719 WIDE, ⇒S/N D117E-01723 NARROW.................................................................. 8-14 OIL COOLED BRAKE..................................................................................................................................... 8-18 BREATHER PLUMBING..................................................................................................................................... 2-52 BUMPERS EXTENDABLE ATTACHMENT S/N D117E-1634⇒.................................................................................................................................. 11-102 C CAM FOLLOWER LEVER TIER II ENGINE .............................................................................................................................................. 2-18 CAMSHAFT ©2005 HYSTER COMPANY i See Service Manual for service procedures.

UNIT CODE D117 EUROPE 10/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE C (continued) TIER II ENGINE .............................................................................................................................................. 2-36 CHARGED AIR COOLER S/N D117E01751Y⇒ (C325), S/N D117E01771Z⇒ (C290) ........................................................................ 2-136 CONTAINER ATTACHMENT INSTALLATION S/N D117E-1634⇒ ....................................................................................................................................... 11-12 CONTAINER HANDLING ATTACHMENT ELECTRICAL ................................................................................................................................................ 11-46 CONTROL LIFT AND TILT ................................................................................................................................................ 9-54 CONTROL VALVE ATTACHMENT ⇒S/N D117E-1587.................................................................................................................................... 9-104 S/N D117E-1503⇒ ......................................................................................................................................... 9-78 S/N D117E-1588⇒ ......................................................................................................................................... 9-82 CONTROL VALVE ATTACHING PARTS ONE FUNCTION ⇒S/N D117E-1681...................................................................................................................................... 9-64 S/N D117E-1682⇒ ......................................................................................................................................... 9-74 TWO FUNCTION ⇒S/N D117E-1681...................................................................................................................................... 9-68 WITH ANTI-SLACK AND LIFT INTERRUPT S/N D117E-1634⇔S/N D117E-1681 .......................................................................................................... 9-72 COOLANT HEATER STARTING AID TIER II ENGINE .............................................................................................................................................. 2-88 COOLING C290 ENGINE (TIER I) ................................................................................................................................. 2-138 C325 ENGINE ⇒S/N D117E01750Y ................................................................................................................................ 2-142 OIL COOLED BRAKE..................................................................................................................................... 8-22 TIER II S/N D117E01751Y⇒ (C325), S/N D117E01771Z⇒ (C290) ..................................................................... 2-144 CORROSION RESISTOR ................................................................................................................................ 2-118 COUNTERWEIGHTS ......................................................................................................................................... 1-40 CRANKSHAFT TIER II ENGINE .............................................................................................................................................. 2-15 CRANKSHAFT MAIN BEARINGS TIER II ENGINE .............................................................................................................................................. 2-24 CYLINDER EXTENDABLE ATTACHMENT...................................................................................................................... 11-74 FIXED ATTACHMENT WITHOUT SLEWING ............................................................................................... 11-72 FORK POSITIONER..................................................................................................................................... 12-37 TWIST LOCK S/N A660E-1352⇔S/N D117E-1633 ........................................................................................................ 11-82 ⇒S/N A660E-1531 .................................................................................................................................... 11-80 S/N D117E-1634⇒.................................................................................................................................... 11-84 CYLINDER BLOCK TIER II ENGINE ................................................................................................................................................ 2-6 CYLINDER BLOCK PLUMBING TIER II ENGINE .............................................................................................................................................. 2-25 CYLINDER HEAD ii ©2005 HYSTER COMPANY See Service Manual for service procedures.

10/2005 UNIT CODE D117 EUROPE TABLE OF CONTENTS (Continued) DESCRIPTION PAGE C (continued) TIER II ENGINE ................................................................................................................................................ 2-8 CYLINDER LINER TIER II ENGINE .............................................................................................................................................. 2-10 D DEDICATED CARRIAGE ELECTRICAL ................................................................................................................................................ 11-44 ⇒S/N D117E-1636 ....................................................................................................................................... 12-40 S/N D117E-1637⇒ ....................................................................................................................................... 12-44 DIFFERENTIAL ⇒S/N D117E-01709X INC. 1712 WIDE, ⇒S/N D117E-01723 NARROW ..................................................... 6-14 S/N D117E01710X⇔S/N D117E01799A EXC. 1712 (WIDE), S/N D117E01724⇔S/N D117E01804A (NARROW).................................................................................................................................................... 6-18 DIFFERENTIAL CARRIER S/N D117E01805A⇒ INC. 1797 (NARROW), S/N D117E01800A⇒ INC. 1796 (WIDE) ............................... 6-22 DIRECTIONAL CONTROL VALVE ATTACHING PARTS ⇒S/N D117E-1633...................................................................................................................................... 9-34 S/N D117E-1634⇔S/N D117E-1681 .......................................................................................................... 9-36 S/N D117E-1634⇔S/N D117E-1681 .............................................................................................................. 9-38 DOOR RETAINERS CENTER AND LEFT MOUNTED CAB ........................................................................................................... 1-17 DRIVE AXLE DISC BRAKE ⇒S/N D117E-01709X WIDE, ⇒S/N D117E-01723 NARROW..................................................................... 6-2 OIL COOLED BRAKE ⇒S/N D117E-01709X INC. 1712 WIDE, ⇒S/N D117E-01723 NARROW.................................................... 6-6 WET BRAKE S/N D117E01710X⇔S/N D117E01799A EXC. 1712 (WIDE), S/N D117E01724⇔S/N D117E01804A (NARROW)........................................................................................................................ 6-10 DRIVE PULLEY AIR COMPRESSOR ....................................................................................................................................... 2-46 WATER PUMP TIER II ENGINE ........................................................................................................................................ 2-126 DRIVE TRAIN FRONT GEAR ................................................................................................................................................ 2-56 E ELECTRICAL CHASSIS C325 ENGINE S/N D117E01751Y⇒............................................................................................................................... 4-10 SHEET 1 OF 2 .............................................................................................................................................. 4-4 SHEET 2 OF 2 .............................................................................................................................................. 4-8 SIDE-SHIFT CARRIAGE ⇒S/N D117E-1633.................................................................................................................................... 12-12 S/N D117E-1634⇒.................................................................................................................................... 12-14 ELECTRICAL ACCESSORIES TIER II ENGINE ............................................................................................................................................ 4-118 ©2005 HYSTER COMPANY iii See Service Manual for service procedures.

UNIT CODE D117 EUROPE 10/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE E (continued) ELECTRONIC FOOT PEDAL MOUNT ............................................................................................................... 3-22 ENGINE ASSEMBLY ............................................................................................................................................ 2-4 ENGINE CONTROL SYSTEM TIER II ENGINE .............................................................................................................................................. 2-34 ENGINE MOUNT.............................................................................................................................................. 2-156 EXHAUST S/N D117E-01582Y⇔S/N D117E-01762Y ................................................................................................... 2-152 S/N D117E-01763Z⇒ ................................................................................................................................... 2-154 ⇒S/N D117E-1581 ....................................................................................................................................... 2-150 EXHAUST MANIFOLD TIER I ENGINE ............................................................................................................................................. 2-110 TIER II ENGINE ............................................................................................................................................ 2-112 EXTENDABLE ATTACHMENT FORK MOUNTED......................................................................................................................................... 11-16 GANTRY MOUNTED .................................................................................................................................... 11-18 HYDRAULIC FORK MOUNTED S/N D117E-1634⇒ ................................................................................................................................ 11-34 GANTRY MOUNTED S/N D117E-1634⇒ ................................................................................................................................ 11-36 S/N D117E-1634⇒.................................................................................................................................... 11-28 HYDRAULIC STOP S/N D117E-1634⇒.................................................................................................................................... 11-38 HYDRAULIC WITH DEDICATED CARRIAGE ⇒S/N D117E-1633.................................................................................................................................... 11-24 S/N D117E-1634⇒.................................................................................................................................... 11-32 HYDRAULIC WITH SIDE-SHIFT CARRIAGE ⇒S/N D117E-1633.................................................................................................................................... 11-20 ⇒S/N D117E-1633 ......................................................................................................................................... 11-8 WITH DEDICATED CARRIAGE S/N D117E1634⇒..................................................................................................................................... 11-14 EXTENDABLE CONTAINER ATTACHMENT ELECTRICAL ⇒S/N D117E-1633.................................................................................................................................... 11-50 S/N D117E-1634⇒.................................................................................................................................... 11-52 F FAN................................................................................................................................................................... 2-128 FAN DRIVE TIER I ENGINE ............................................................................................................................................... 2-58 TIER II ENGINE .............................................................................................................................................. 2-60 FIRE EXTINGUISHER ..................................................................................................................................... 12-38 FIXED ATTACHMENT DEDICATED CARRIAGE MOUNTED............................................................................................................. 11-6 HYDRAULIC ................................................................................................................................................. 11-40 ⇒S/N D117E-1633 ......................................................................................................................................... 11-4 FLOOR PLATES AND COVERS ........................................................................................................................ 1-20 FLOW AMPLIFIER ............................................................................................................................................. 7-14 ATTACHING PARTS iv ©2005 HYSTER COMPANY See Service Manual for service procedures.

10/2005 UNIT CODE D117 EUROPE TABLE OF CONTENTS (Continued) DESCRIPTION PAGE F (continued) ⇒S/N D117E-1681...................................................................................................................................... 7-16 S/N D117E-1682⇒...................................................................................................................................... 7-18 FLOW VALVE EXTENDABLE ATTACHMENT...................................................................................................................... 11-94 FLYWHEEL TIER I ENGINE ............................................................................................................................................... 2-62 FLYWHEEL HOUSING TIER II ENGINE .............................................................................................................................................. 2-28 FORK 5.5 X 12......................................................................................................................................................... 12-36 FORK POSITIONER ........................................................................................................................................ 12-34 FRONT ENGINE SUPPORT .............................................................................................................................. 2-44 FRONT GEAR COVER TIER II ENGINE .............................................................................................................................................. 2-30 FUEL FILTER TIER I ENGINE ................................................................................................................................................. 3-4 TIER II ENGINE ................................................................................................................................................ 3-6 FUEL FILTER PLUMBING TIER I ENGINE ................................................................................................................................................. 3-8 TIER II ENGINE .............................................................................................................................................. 3-10 FUEL PLUMBING TIER II ENGINE .............................................................................................................................................. 3-18 FUEL PUMP ASSEMBLY TIER II ENGINE .............................................................................................................................................. 3-14 FUEL PUMP COUPLING TIER II ENGINE .............................................................................................................................................. 3-17 FUEL PUMP DRIVE TIER II ENGINE .............................................................................................................................................. 3-12 FUEL SYSTEM..................................................................................................................................................... 3-2 G GANTRY CARRIAGE WITH MECHANICAL PILE SLOPE S/N D117E-1634⇒.................................................................................................................................... 12-54 WITH POWER PILE SLOPE SHEET 1 OF 2 S/N D117E-1634⇒ ................................................................................................................................ 12-46 SHEET 2 OF 2 S/N D117E-1634⇒ ................................................................................................................................ 12-50 GEAR HOUSING TIER II ENGINE .............................................................................................................................................. 2-16 GENERAL TRUCK ............................................................................................................................................... 1-2 H HANGER ASSEMBLY S/N D117E-1634⇒ ....................................................................................................................................... 12-56 HEADER HOSE ................................................................................................................................................. 12-4 HEATER ............................................................................................................................................................. 1-28 HEATER CONTROL ........................................................................................................................................... 1-30 ©2005 HYSTER COMPANY v See Service Manual for service procedures.

UNIT CODE D117 EUROPE 10/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE H (continued) HOODS ⇒S/N D117E-1581 ......................................................................................................................................... 1-32 S/N D117E-1582⇒ ......................................................................................................................................... 1-36 HOSE SHEAVE EXTENDABLE ATTACHMENT...................................................................................................................... 11-88 HUB AND SHAFT S/N D117E01800A⇒ INC. 1796 (WIDE), S/N D117E01805A⇒ INC. 1797 (NARROW) ............................... 6-28 HYDRAULIC SUPPLY AND RETURN ⇒S/N D117E-1681........................................................................................................................................ 9-4 S/N D117E-1682⇒........................................................................................................................................ 9-8 HYDRAULIC LINES ATTACHMENT CONTROL .............................................................................................................................. 9-15 JUNCTION BLOCK AND TWO-SPEED VALVE ............................................................................................. 9-18 HYDRAULIC PUMP MAIN ............................................................................................................................................................. 9-108 STEERING ⇒S/N D117E01776Z................................................................................................................................. 9-110 S/N D117E01777Z⇒................................................................................................................................. 9-112 HYDRAULIC TANK ............................................................................................................................................. 9-50 HYDRAULIC VALVE MOUNTING PLATE S/N D117E-1682⇒ ......................................................................................................................................... 9-12 HYDRAULICS SIDE-SHIFT CARRIAGE STANDARD MAST S/N D117E-1634⇒ ................................................................................................................................ 12-24 WIDE MAST ⇒S/N D117E-1633 ................................................................................................................................ 12-20 S/N D117E-1634⇒ ................................................................................................................................ 12-28 SIDE-SHIFT CYLINDER STANDARD MAST ⇒S/N D117E-1633 ................................................................................................................................ 12-16 I IDLER GEAR TIER II ENGINE .............................................................................................................................................. 2-22 INDICATOR TWIST LOCK ................................................................................................................................................ 11-86 INJECTOR TIER II ENGINE .............................................................................................................................................. 3-20 INLET CONNECTOR AIR COMPRESSOR TIER II ENGINE .......................................................................................................................................... 2-26 INSTRUMENT CLUSTER C325, AND TIER II ENGINE ........................................................................................................................... 4-20 INSTRUMENT PANEL SHEET 1 OF 2 ................................................................................................................................................ 4-12 SHEET 2 OF 2 ................................................................................................................................................ 4-16 INTAKE MANIFOLD vi ©2005 HYSTER COMPANY See Service Manual for service procedures.

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Hyster D117 (H36.00-48.00E, H36.00-H48.00E-16CH) Forklift Parts Manual

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