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Hyster A416 Service Manual – PDF DOWNLOAD
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Description
Hyster A416 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A416 Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster A416 Service Manual – PDF DOWNLOAD
1534737-2200SRM1058-(03-2005)-US-EN............................................. 1 toc......................................................................... 1 Troubleshooting and Adjustments Using the AC Controls Program........... 1 Safety Precautions Maintenance and Repair............................... 2 General................................................................. 5 Computer Requirements............................................... 5 Software, Install................................................... 5 Language Selection.................................................. 5 Demo Mode........................................................... 6 Connect PC to Lift Truck............................................ 8 Starting AC Controls Program........................................ 9 Lift Truck Control Setup................................................ 13 Change Lift Truck Serial Number or Hourmeter........................ 13 Setting Factory Default Values or Changing Lift Truck Parameters.... 14 Create New Custom Lift Truck Configuration.......................... 18 Lift Truck Configuration Properties................................. 22 Import New Lift Truck Configuration From Disk....................... 25 Delete Custom Lift Truck Configuration or Password File............. 27 Dash Display............................................................ 29 Custom Display Languages............................................ 29 Download Display Language........................................... 31 Clear Operator Log.................................................. 32 Clear Status Log.................................................... 35 Password Functions...................................................... 35 Enable/Disable Password and Lift Truck Inspection Functions......... 35 Truck Inspection Checklist...................................... 35 Password........................................................ 35 Password Properties................................................. 38 Create New Password File............................................ 41 Download Passwords.................................................. 42 Upload Passwords.................................................... 44 Reports Menu............................................................ 46 Passwords........................................................... 46 Status Codes........................................................ 49 Operators........................................................... 52 Current Settings.................................................... 55 Troubleshooting......................................................... 58 Diagnostics......................................................... 58 Help Menu............................................................... 61 General............................................................. 61 Contents............................................................ 61 Technical Support................................................... 63 About Electric Truck AC Controls Program............................ 65 1534739-8000SRM1060-(03-2003)-US................................................ 71 toc......................................................................... 71 Periodic Maintenance.................................................... 71 Safety Precautions Maintenance and Repair............................... 72 General................................................................. 75 Serial Number Data.................................................. 75 How to Move Disabled Lift Truck..................................... 75 How to Tow Lift Truck........................................... 75 How to Put Lift Truck on Blocks..................................... 76 How to Raise Drive Tires........................................ 76 How to Raise Steering Tires..................................... 76 Maintenance Schedule.................................................... 77 Maintenance Procedures Every 8 Hours or Daily........................... 81 How to Make Checks With Key OFF..................................... 81 Tires and Wheels................................................ 81 Forks........................................................... 81 Adjust...................................................... 81 Remove...................................................... 82 Install..................................................... 83 Forks, Mast, and Lift Chains, Inspect........................... 83 Safety Labels................................................... 83 Steering Column Latch........................................... 83 Operator Restraint System....................................... 84 Battery Restraint System ....................................... 84 Battery......................................................... 85 Hydraulic System................................................ 85 How to Make Checks With Key ON...................................... 86 Gauges, Horn, and Fuses......................................... 86 Steering System................................................. 86 Service Brakes.................................................. 86 Parking Brake................................................... 86 Control Levers and Pedals....................................... 86 Direction and Speed Control Pedals.............................. 86 Lift System Operation........................................... 87 Maintenance Procedures Every 500 Hours or 3 Months...................... 87 Wheel Nut Torques................................................... 87 Mast................................................................ 87 Forks............................................................... 88 Parking Brake Adjustment............................................ 88 Maintenance Procedures Every 1000 Hours or 6 Months..................... 88 Lift Chains......................................................... 88 Lift Chains......................................................... 89 Wear Check...................................................... 89 Forks............................................................... 89 Check Upper and Lower Bearings, Integral Sideshift Carriage......... 90 Steering Tie Rods................................................... 90 Steering Axle Spindles.............................................. 90 King Pins....................................................... 90 Hydraulic Tank Breather............................................. 90 Differential and Speed Reducer...................................... 91 Brake Fluid......................................................... 91 Electrical Inspection............................................... 92 Contactors...................................................... 92 Motor Brushes (Optional DC Pump)................................ 92 Motor Brushes, General...................................... 92 Other Lubrication................................................... 93 Maintenance Procedures Every 2000 Hours or Yearly....................... 94 Hydraulic System.................................................... 94 Change Filter for Hydraulic Oil................................. 94 Change Hydraulic Oil............................................ 94 Differential and Speed Reducer...................................... 94 Service Brakes...................................................... 95 Wheel Bearings...................................................... 95 Steer Wheels, Lubrication....................................... 95 Drive Wheels, Lubrication....................................... 95 Lift Chains......................................................... 96 Replace Upper and Lower Bearings, Integral Sideshift Carriage....... 96 Other Lubrication................................................... 96 Battery Maintenance..................................................... 96 How to Charge Battery............................................... 96 How to Change Battery............................................... 98 General......................................................... 98 Lift and Tilt System Leak Check......................................... 99 Lift Cylinders Leak Check........................................... 99 Tilt Cylinders Leak Check...........................................100 Safety Procedures When Working Near Mast................................100 Lift Chain Adjustments..................................................103 Welding Repairs.........................................................105 Overhead Guard Changes..................................................105 Wheels and Tire Maintenance.............................................106 Pneumatic Tires and Wheels .........................................106 Remove Wheels From Lift Truck...................................106 Remove Wheel From Pneumatic Tire................................107 Install Wheel in Pneumatic Tire.................................108 Install Three- or Four-Piece Wheel in Pneumatic Tire............109 Add Air to Tires................................................110 Wheels, Install.................................................110 Solid Rubber Tires on Pneumatic Wheels..............................111 Remove Wheels From Lift Truck...................................111 Remove Solid Rubber Tire From Pneumatic Wheel...................111 Install Solid Rubber Tire on Pneumatic Wheel....................112 Wheels, Install.................................................114 SIT Tire, Change....................................................114 Remove SIT Solid Tire From Wheel................................115 Install SIT Solid Tire on Wheel.................................116 Adhesives and Sealants..................................................117 tables...................................................................... 71 Table 1. Maintenance Schedule........................................... 78 Table 2. Hook-Type Carriage Chain Adjustment............................104 Table 3. Pin-Type Carriage Chain Adjustment.............................104 1554626-0100SRM1073-(06-2004)-US-EN.............................................121 toc.........................................................................121 Frame...................................................................121 Safety Precautions Maintenance and Repair...............................122 Introduction............................................................125 General.............................................................125 Description of Operation............................................125 Discharging the Capacitors..........................................126 Covers and Floor Plates.................................................127 Overhead Guard Repair...................................................129 Remove..............................................................129 Install.............................................................129 Hood and Seat Assembly..................................................130 Remove..............................................................131 Install.............................................................131 Counterweight...........................................................132 Remove..............................................................132 Install.............................................................133 Safety Labels...........................................................134 Painting Instructions...................................................137 1554627-1300SRM1074-(06-2004)-US-EN.............................................141 toc.........................................................................141 Transaxle...............................................................141 Safety Precautions Maintenance and Repair...............................142 Introduction............................................................145 General.............................................................145 Discharging the Capacitors..........................................145 Description.............................................................147 Transmission........................................................147 Traction Motor......................................................147 Maintenance.............................................................148 Oil Level Check.....................................................148 Oil Change..........................................................148 Transaxle Assembly......................................................149 Remove..............................................................149 Disassemble.........................................................150 Traction Motor and Covers.......................................150 Brake Assembly and Gears........................................151 Planetary Gears and Drive Axle..................................153 Clean and Inspect...................................................154 Assemble............................................................155 Planetary Gears and Drive Axle..................................155 Brake Assembly and Gears........................................156 Traction Motor and Covers.......................................157 Install.............................................................159 Troubleshooting.........................................................160 tables......................................................................141 Table 1. Special Tools..................................................157 Table 2. Conventional Tools.............................................158 1554628-1600SRM1075-(03-2004)-US-EN.............................................165 toc.........................................................................165 Steering System.........................................................165 Safety Precautions Maintenance and Repair...............................166 Introduction............................................................169 General.............................................................169 Discharging the Capacitors..........................................169 Description of Operation................................................171 Steering Pressure Check.................................................171 Operation Check.........................................................173 Steering Wheel and Column...............................................173 Steering Column Covers..............................................173 Remove..........................................................173 Install.........................................................173 Steering Column Components..........................................174 Remove..........................................................174 Install.........................................................177 Steering Control Unit Assembly..........................................178 Power Steering Pump and Motor...........................................178 Description.........................................................178 Remove..............................................................178 Install.............................................................180 Disassemble.........................................................180 Assemble............................................................180 Steering Actuator Components............................................182 Steer Tire and Wheel Assembly.......................................182 Remove..........................................................182 Install.........................................................182 Wheel Hub Assembly..................................................182 Remove..........................................................182 Install.........................................................183 Steering Axle Assembly..............................................183 Remove..........................................................183 Clean...........................................................185 Install.........................................................185 Troubleshooting.........................................................186 1554629-1800SRM1076-(03-2004)-US-EN.............................................191 toc.........................................................................191 Brake System............................................................191 Safety Precautions Maintenance and Repair...............................192 Introduction............................................................195 General.............................................................195 Discharging the Capacitors..........................................195 Brake Pedal Assembly....................................................197 Remove..............................................................197 Disassemble.........................................................198 Assemble............................................................198 Install.............................................................198 Master Cylinder.........................................................198 Remove..............................................................198 Install.............................................................199 Adjustments.........................................................200 Bleed the Brake System..........................................200 Adjust Linkage..................................................200 Brake Lines.............................................................200 Parking Brake...........................................................201 Remove..............................................................201 Disassemble.........................................................201 Assemble............................................................203 Install.............................................................203 Troubleshooting.........................................................203 1554631-2000SRM1085-(03-2004)-US-EN.............................................207 toc.........................................................................207 HUSCO™ Main Control Valve...............................................207 Safety Precautions Maintenance and Repair...............................208 General.................................................................211 Description.............................................................211 Operation...............................................................211 Lift Section........................................................214 Tilt Section........................................................214 Tilt Backward...................................................214 Tilt Forward....................................................214 Relief Valve........................................................216 Main Control Valve Repair...............................................217 Remove..............................................................217 Disassemble.........................................................219 Clean and Inspect...................................................219 Assemble............................................................219 Install.............................................................221 Pressure Relief Valve Check and Adjustment..............................224 Primary Relief Valve................................................224 Secondary Relief Valve..............................................224 Troubleshooting.........................................................225 1554632-2000SRM1086-(06-2004)-US-EN.............................................229 toc.........................................................................229 Electro-Hydraulic Control Valve.........................................229 Safety Precautions Maintenance and Repair...............................230 General.................................................................233 Description.............................................................233 Electro-Hydraulic Control System....................................233 Electro-Hydraulic Control Valve.....................................234 Valve Driver Module.................................................237 Manual Lowering Valve...............................................237 Hydraulic Lever Console.............................................237 Electro-Hydraulic Control Valve.........................................237 Remove..............................................................237 Disassemble.........................................................238 Clean and Inspect...................................................238 Assemble............................................................239 Lift Valve Section..............................................239 Tilt/Auxiliary Valve Sections...................................239 Valve Spool Coils...............................................240 Fittings........................................................240 Install.............................................................240 Check and Adjust....................................................241 Tilt Counterbalance Valve.......................................241 Main Relief Valve...............................................241 Auxiliary Relief Valve..........................................241 Valve Driver Module.....................................................241 Remove..............................................................241 Install.............................................................242 Hydraulic Lever Console.................................................242 Remove..............................................................242 Disassemble.........................................................242 Covers..........................................................242 Hydraulic Control Lever.........................................242 Main PC Board...................................................242 Assemble............................................................243 Main PC Board...................................................243 Hydraulic Control Lever.........................................243 Covers..........................................................243 Install.............................................................243 Troubleshooting.........................................................244 Troubleshooting Chart...............................................244 tables......................................................................229 Table 1. Error Codes....................................................244 1554633-2200SRM1087-(02-2005)-US-EN.............................................251 toc.........................................................................251 AC Motor Controllers/Display Panel......................................251 Safety Precautions Maintenance and Repair...............................252 Description.............................................................255 General.............................................................255 Description.........................................................255 AC Motors.......................................................255 ZAPI™ AC Motor Controller.......................................255 Principles of Operation.........................................256 Controller Thermal Management...................................257 Controller Area Network (CAN Bus)...............................257 Discharging the Capacitors..........................................257 AC Motor Controller Repair..............................................258 General.............................................................258 Special Precautions.............................................258 Thermal Sensors.....................................................259 Motor Controller, Replace...........................................259 Controller Checks and Adjustments.......................................259 Function Parameters.....................................................260 General.............................................................260 Function Parameter Descriptions.........................................261 Parameters..........................................................261 Top Speed Forward...............................................261 Top Speed Reverse...............................................261 Acceleration....................................................261 Regen Braking...................................................262 Auto Deceleration...............................................262 Extended Shift..................................................262 Pump Acceleration...............................................262 Tilt/Auxiliary Pump Acceleration................................262 Low Lift Speed..................................................262 Maximum Lift Speed..............................................262 Maximum Lowering Speed..........................................262 Tilt Speed......................................................262 3rd Function....................................................263 3rd Function Speed..............................................263 4th Function....................................................263 4th Function Speed..............................................263 Battery Voltage.................................................263 Lift Interrupt..................................................263 BDI Adjustment..................................................263 BDI Decrement Time..............................................263 Service Reminder................................................264 Custom..........................................................264 Restore Defaults................................................264 Calibration Parameters..................................................264 Throttle Calibration................................................264 Steering Calibration................................................264 Display Panel...........................................................264 General.............................................................264 Premium Display Panel...........................................264 Standard Display Panel..........................................265 Display Functions and Features..........................................266 Key-On Initialization...............................................266 Standard Display....................................................267 Premium Display.....................................................267 Lift Truck Inspection Function......................................267 Access to Service Functions.........................................268 Service Functions...................................................268 Performance Modes...................................................269 Battery Discharge Indication (BDI)..................................270 Hourmeter...........................................................270 Status Code List....................................................270 Dash Display Service Menu Navigation....................................271 General.............................................................271 Moving Through Menu Selections......................................271 Editing and Adding Information......................................271 Troubleshooting.........................................................272 General.............................................................272 Status Codes........................................................272 Controller Connector Pin Outs.......................................333 Valve Driver Module (Electro-Hydraulic Valve Option)................334 Hydraulic Lever Console (Electro-Hydraulic Option Only).............335 Dash Display........................................................335 System Logic Diagrams...............................................336 tables......................................................................251 Table 1. Traction Parameters............................................260 Table 2. Transistor Lift With Manual Valve Parameters...................260 Table 3. Transistor Lift With Electro-Hydraulic Valve Parameters........261 Table 4. List of Status Codes...........................................273 Table 5. Connector A....................................................333 Table 6. Connector C....................................................333 Table 7. Connector D - Standard Model...................................334 Table 8. Connector D - Premium Model....................................334 Table 9. Connector B....................................................334 Table 10. Connector C...................................................335 1554634-2200SRM1078-(11-2004)-US-EN.............................................341 toc.........................................................................341 Electrical System.......................................................341 Safety Precautions Maintenance and Repair...............................342 Introduction............................................................345 General.............................................................345 Discharging the Capacitors..........................................345 Emissions...........................................................347 Electromagnetic Interference....................................347 Motor Controllers.......................................................347 Controllers.........................................................347 Remove..........................................................347 Install.........................................................348 Hydraulics Contactor................................................349 Remove..........................................................349 Disassemble.....................................................349 Assemble........................................................349 Install.........................................................349 Contactor Panel.........................................................350 Main Contactor......................................................350 Remove..........................................................350 Disassemble.....................................................351 Assemble........................................................351 Install.........................................................352 Contactor Coil..................................................352 Contactor Tips..................................................352 Fuses...............................................................352 Display Units...........................................................353 Features............................................................353 Replace.............................................................354 Key Switch..............................................................354 Replace.............................................................354 Directional Controls....................................................356 Directional Control Switches........................................356 Accelerator Switches and Pedal Assembly.............................357 Install.............................................................357 Calibrate...........................................................360 MONOTROL™ Directional Control.......................................360 Brakes..................................................................362 Brake Switch........................................................362 Adjust or Replace...............................................362 Master Cylinder Indicator...........................................362 Parking Brake Disengage.............................................363 Override Mode...................................................363 Horn Components and Steering Encoder....................................364 Horn Components.....................................................364 Horn............................................................364 Horn Button and Contacts........................................365 Steering Encoder....................................................365 Hood and Seat Switches..................................................366 Hood Position Switches..............................................366 Seat Switch.........................................................366 Steer Angle Potentiometer...............................................366 General.............................................................366 Operation...........................................................366 Example.........................................................367 Position Steer Tire for Straight Travel.............................367 Install.............................................................368 Set Potentiometer to Midpoint...................................368 Install to Steer Axle...........................................368 Calibrate.......................................................369 Test................................................................369 Wiring Harness..........................................................370 tables......................................................................341 Table 1. Potentiometer Specifications...................................369 1554635-8000SRM1079-(06-2004)-US-EN.............................................377 toc.........................................................................377 Periodic Maintenance....................................................377 Safety Precautions Maintenance and Repair...............................378 Introduction............................................................381 General.............................................................381 Discharging the Capacitors..........................................381 How to Move Disabled Lift Truck.....................................383 How to Tow Lift Truck...........................................383 How to Put Lift Truck on Blocks.....................................384 How to Raise Drive Tires........................................384 How to Raise Steer Tires........................................385 Safety Procedures When Working Near Mast................................385 Maintenance Schedule....................................................387 Maintenance Procedures Every 8 Hours or Daily...........................392 Checks With the Key Switch OFF......................................392 Safety Labels and Decals........................................392 Frame...........................................................392 Wheels and Tires................................................392 Mast, Carriage, and Forks.......................................392 Hydraulic Oil Level and Leaks...................................393 Operator and Battery Restraints.................................394 Battery Check...................................................394 Checks With the Key Switch ON.......................................395 Electrical Components...........................................395 Directional Speed Control.......................................395 Steering System.................................................395 Hydraulic System................................................395 Brakes..........................................................396 Maintenance Procedures Every 500 Hours or 3 Months......................396 Tire and Wheel Assemblies...........................................396 Mast and Carriage...................................................396 Battery.............................................................397 Parking Brakes......................................................398 Transaxle...........................................................399 Maintenance Procedures Every 1000 Hours or 6 Months.....................400 Lift Chains.........................................................400 Hydraulic Breather Cap..............................................400 Master Cylinder.....................................................401 Electrical Inspection...............................................401 Hydraulic Motor Brushes.........................................401 Contactors......................................................401 Directional Speed Control.......................................402 Transaxle, Oil Change...............................................402 Maintenance Procedures Every 2000 Hours or Yearly.......................403 Steering............................................................403 Hydraulic...........................................................404 Hydraulic Oil Filter, Change....................................404 Hydraulic Oil Strainer, Check...................................404 Hydraulic Oil, Change...........................................404 General Repairs.........................................................405 Welding Repairs.....................................................405 Painting Instructions...............................................406 Lift and Tilt System Leak Check.........................................406 Lift System.........................................................406 Tilt System.........................................................407 Battery Maintenance.....................................................408 How to Charge Battery...............................................408 How to Change Battery...............................................409 Battery Size Specifications.........................................409 tables......................................................................377 Table 1. Maintenance Schedule...........................................388 1554636-8000SRM1080-(11-2004)-US-EN.............................................413 toc.........................................................................413 Capacities and Specifications...........................................413 Safety Precautions Maintenance and Repair...............................414 General.................................................................417 Hydraulic System........................................................418 Steering System.........................................................419 Tire Sizes..............................................................420 Torque Specifications...................................................421 Electrical..........................................................421 Steering System.....................................................421 Hydraulic System....................................................421 Manual Hydraulic Valve..............................................421 Transaxle...........................................................421 Transaxle Assembly......................................................422 Travel Speeds...........................................................423 Battery.................................................................424 1554637-8000SRM1081-(11-2004)-US-EN.............................................431 toc.........................................................................431 Diagrams................................................................431 Safety Precautions Maintenance and Repair...............................432 1566043-0620SRM1115-(06-2004)-US-EN.............................................463 toc.........................................................................463 AC Traction Motor Repair................................................463 Safety Precautions Maintenance and Repair...............................464 Introduction............................................................467 General.............................................................467 Discharging the Capacitors..........................................467 Description.............................................................469 Traction Motor......................................................469 AC Motor Repair.........................................................470 Remove..............................................................470 Disassemble.........................................................470 Inspect.............................................................470 Assemble............................................................470 Install.............................................................472 Troubleshooting.........................................................472 a416es#1 (2)....................................................................477
HYSTER A416 SERVICE MANUAL – PDF DOWNLOAD:
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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