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Hyster B108 (E30-50B, E60BS, E60-120B) Service Manual – PDF DOWNLOAD
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Description
Hyster B108 (E30-50B, E60BS, E60-120B) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster B108 (E30-50B, E60BS, E60-120B) Service Manual – PDF DOWNLOAD
Language : English
Pages : 472
Downloadable : Yes
File Type : PDF
Size: 11.8 MB
TABLE OF CONTENTS:
Hyster B108 (E30-50B, E60BS, E60-120B) Service Manual – PDF DOWNLOAD
Battery Discharge Indicators.................................................................................................................... 1 INTRODUCTION................................................................................................................................ 1 GENERAL................................................................................................................................. 1 INDICATORS WITH METER MOVEMENTS......................................................................................................... 2 BATTERY INDICATORS WITH LCD OR LED DISPLAYS............................................................................................. 3 Liquid Crystal Displays............................................................................................................. 3 Light Emitting Diode Displays....................................................................................................... 7 CHECKS AND ADJUSTMENTS...................................................................................................................... 9 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS................................................................................. 9 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.................................................................................... 9 Reset Potentiometer................................................................................................................. 9 Specific Gravity Alarm.............................................................................................................. 10 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS................................................................................. 11 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.................................................................................... 11 Reset Potentiometer................................................................................................................. 11 Discharge Potentiometer............................................................................................................. 11 LED DISPLAY WITH LIFT INTERRUPT......................................................................................................... 12 CHECKING CURTIS 933-1 METER............................................................................................................. 12 Reset Check......................................................................................................................... 12 Discharge Check..................................................................................................................... 13 Lockout Check....................................................................................................................... 13 LED's Do Not Illuminate............................................................................................................. 14 Hourmeter Check..................................................................................................................... 14 Hour Glass Icon..................................................................................................................... 14 ADJUSTMENT OF CURTIS 933-1 METER.................................................................................................... 14 CHECKING CURTIS 1215 BATTERY INDICATOR.............................................................................................. 14 ADJUSTING CURTIS 1215 BATTERY INDICATOR............................................................................................. 15 Voltage Selection............................................................................................................... 16 ADJUSTING BDI OF SEM DISPLAY PANEL.................................................................................................. 17 REPAIRS................................................................................................................................. 17 BATTERY INDICATORS.................................................................................................................. 17 Replacement..................................................................................................................... 17 CONTROLLER FOR THE BATTERY INDICATOR................................................................................................ 17 Replacement..................................................................................................................... 17 DISPLAY PANEL COMPONENTS............................................................................................................ 17 REPLACING SEM DISPLAY PANEL......................................................................................................... 17 SEM Display Panel REMOVAL........................................................................................................... 19 Removal And Replacement......................................................................................................... 19 Brake System.................................................................................................................................... 21 INTRODCUTION................................................................................................................................ 21 General................................................................................................................................. 21 Description and Operation............................................................................................................... 21 REPAIRS..................................................................................................................................... 22 Removal and Disassembly................................................................................................................. 23 Cleaning................................................................................................................................ 23 Inspection.............................................................................................................................. 24 Assembly and Installation............................................................................................................... 24 CHECKS AND ADJUSTMENTS...................................................................................................................... 26 Manual Adjustment for the Service Brakes................................................................................................ 26 Removing the Air from the Brake System.................................................................................................. 27 TROUBLESHOOTING............................................................................................................................. 29 Capacities & Specification...................................................................................................................... 31 DC Motor Maintenance............................................................................................................................ 38 INTRODUCTION................................................................................................................................ 38 MAGNETISM................................................................................................................................... 38 MAGNETISM AND PERMANENT MAGNETS......................................................................................................... 38 ELECTROMAGNETIC FIELDS.................................................................................................................. 38 ELECTROMAGNETS.......................................................................................................................... 39 ELECTROMAGNETIC INDUCTION............................................................................................................... 40 MAGNETIC FORCE ON A CONDUCTOR........................................................................................................... 40 BASIC MOTORS................................................................................................................................ 41 MOTOR OPERATION......................................................................................................................... 41 COMMUTATION PRINCIPLE................................................................................................................... 42 DIRECTION OF MOTOR ROTATION............................................................................................................. 42 MOTOR SPEED............................................................................................................................. 42 MOTOR TORQUE............................................................................................................................ 43 COUNTER ELECTROMOTIVE FORCE............................................................................................................. 43 TYPICAL MOTOR........................................................................................................................... 43 TYPES OF MOTORS......................................................................................................................... 43 Permanent–Magnet.................................................................................................................... 43 Series Wound........................................................................................................................ 44 Parallel or Shunt Wound............................................................................................................. 45 Compound Wound...................................................................................................................... 45 MOTOR INSULATION CLASS.................................................................................................................. 46 STORAGE................................................................................................................................. 46 HANDLING................................................................................................................................ 46 BREAK–IN OPERATION...................................................................................................................... 46 CLEANING................................................................................................................................ 47 BASIC REPAIR GUIDELINES................................................................................................................. 47 BEARINGS, SEALS AND LUBRICATION......................................................................................................... 48 BRUSHES AND BRUSH HOLDERS............................................................................................................... 48 ARMATURE................................................................................................................................ 49 COMMUTATOR.............................................................................................................................. 49 Description......................................................................................................................... 49 SATISFACTORY SURFACE.................................................................................................................... 50 STREAKING AND THREADING SURFACE......................................................................................................... 51 GROOVING ON SURFACE..................................................................................................................... 52 COPPER DRAG ON SURFACE.................................................................................................................. 54 OVERHEATING............................................................................................................................. 54 FIELD ASSEMBLY.......................................................................................................................... 56 INSPECTION CHECKLIST.................................................................................................................... 56 CHECKING AND REPLACING MOTOR BRUSHES.................................................................................................... 56 Inspecting Brushes.................................................................................................................. 56 INSPECT THE COMMUTATOR.................................................................................................................. 57 REPLACING BRUSHES....................................................................................................................... 57 SEATING BRUSHES (STONING PROCEDURE)..................................................................................................... 57 CHECK THE MOTORS FOR OPENS, GROUNDS AND SHORTS.......................................................................................... 58 Check The Motor For Opens........................................................................................................... 58 Check The Motor For Grounds......................................................................................................... 58 Check The Motor For Shorts.......................................................................................................... 58 COMMUTATOR INSPECTION................................................................................................................... 60 POLISHING COMMUTATOR.................................................................................................................... 61 TURNING COMMUTATOR...................................................................................................................... 61 UNDERCUTTING COMMUTATOR................................................................................................................. 61 SLOT RAKING AND BRUSHING COMMUTATOR..................................................................................................... 61 Diagrams (E30-60BS)............................................................................................................................. 63 ELECTRICAL SYSTEM CABLING DIAGRAM........................................................................................................... 63 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM 36/48 VOLT*............................................................................................. 64 ELECTRICAL SYSTEM WIRING DIAGRAM 36/48 VOLT*................................................................................................ 66 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM 72/80 VOLT*............................................................................................. 68 ELECTRICAL SYSTEM WIRING DIAGRAM 72/80 VOLT*................................................................................................ 70 SCHEMATIC DIAGRAM WITH ACCELERATOR BOX 36/48 VOLT........................................................................................... 72 WIRING DIAGRAM WITH ACCELERATOR BOX 36/48 VOLT.............................................................................................. 74 SCHEMATIC DIAGRAM WITH ACCELERATOR BOX 72/80 VOLT........................................................................................... 76 WIRING DIAGRAM WITH ACCELERATOR BOX 72/80 VOLT.............................................................................................. 78 LIFT/TILT HYDRAULIC SYSTEM SCHEMATIC........................................................................................................ 80 Diagrams (E60-120B)............................................................................................................................. 81 FIGURE 1. SCHEMATIC DIAGRAM WITH ACCELERATOR CARD........................................................................................... 82 FIGURE 2. SCHEMATIC DIAGRAM WITH ACCELERATOR CARD AND SEAT BRAKE............................................................................ 84 FIGURE 3. WIRING DIAGRAM WITH ACCELERATOR CARD.............................................................................................. 86 FIGURE 4. WIRING DIAGRAM, 36/48 VOLT EV-1 CONTROL .......................................................................................... 88 FIGURE 5. SCHEMATIC DIAGRAM, 36/48 VOLT EV-1 CONTROL........................................................................................ 90 FIGURE 6. WIRING DIAGRAM, 72/80 VOLT EV-1 CONTROL........................................................................................... 92 FIGURE 7. SCHEMATIC DIAGRAM 72/80 VOLT EV-1 CONTROL......................................................................................... 94 FIGURE 8. SCHEMATIC DIAGRAM, 36/48 VOLT EV-1W CONTROL ...................................................................................... 96 FIGURE 9. WIRING DIAGRAM, 36/48 VOLT EV-1W CONTROL ......................................................................................... 98 FIGURE 10. SCHEMATIC DIAGRAM, 72/80 VOLT EV-1W CONTROL......................................................................................100 FIGURE 11. WIRING DIAGRAM, 72/80 VOLT EV-1W CONTROL ........................................................................................102 Drive Axle......................................................................................................................................103 INTRODUCTION................................................................................................................................103 General.................................................................................................................................103 Description.............................................................................................................................103 REPAIRS.....................................................................................................................................104 Removal.................................................................................................................................104 Installation............................................................................................................................105 Axle Housing For S30-100E And S40-50F Lift Trucks.......................................................................................106 Wheels And Tires........................................................................................................................108 TROUBLESHOOTING.............................................................................................................................110 SPECIFICATIONS..............................................................................................................................111 Electrical System...............................................................................................................................113 ELECTRICAL CHECKS AND ADJUSTMENTS FOR SitDrive) ELECTRICAL LIFT TRUCKS......................................................................113 GENERAL.................................................................................................................................113 CONTROL AND POWER FUSES.................................................................................................................118 CONTROL CARD ADJUSTMENTS................................................................................................................119 Adjusting Creep Speed, "CREEP'......................................................................................................121 Adjusting Controlled Acceleration, "C/A" ...........................................................................................121 Adjusting Current Limit, "C/L"......................................................................................................122 Adjust "1A TIME"....................................................................................................................123 Adjust 1A Drop Out, "1A D.O"........................................................................................................125 Adjust Plugging, "PLUG".............................................................................................................125 Ramp Start..........................................................................................................................125 Adjust Field Weakening Pick Up and Drop Out, "F.W.P.U." And "F.W.D.O."..............................................................125 Adjust "REGEN C/L" (Current Limit)..................................................................................................126 Adjust "REGEN D.O." (Drop Out)......................................................................................................126 PROPORTIONAL CONTROL (J25-35A Only).....................................................................................................129 SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS.................................................................................................130 SCR CONTROL, SINGLE PUMP MOTOR..........................................................................................................130 Accelerator Card (E-20-100B, J40-60AS Only).........................................................................................131 Circuit Description For Accelerator Card Used With A Seat Switch....................................................................132 Accelerator "START" (IC3)...........................................................................................................133 Accelertor "1A TIME" (IC2)..........................................................................................................133 Circuit Description For Accelerator Card Used With A Seat Brake.....................................................................133 Accelerator "START" (IC3)...........................................................................................................134 Accelerator "1A TIME" (IC1 and IC2).................................................................................................134 CHECK THE ACCELERTOR CARD...........................................................................................................134 ADJUSTING THE ACCELERATOR CARD......................................................................................................134 THE POTENTIOMETERS AND CONTOL SWITCHES..................................................................................................134 Steering Potentiometer (J25-35A Only)...............................................................................................134 Accelerator Potentiometer And Start Switch (E20-120XL And J25-60XL Only)............................................................136 Accelerator Potentiometer And Direction Switch......................................................................................137 Adjusting Start Switch..............................................................................................................138 "FORWARD" And "REVERSE" Switch (MONOTROL) (Earlier Production Lift Trucks)..........................................................138 Direction Switches (MONOTROL) (Later Production Lift Trucks)........................................................................139 "FORWARD" And "REVERSE" Switch (Steering Column)....................................................................................140 Hydraulic Pump Switch...............................................................................................................140 Replace The Key Switch..............................................................................................................140 Adjust The Seat Switch..............................................................................................................140 Adjust The Brake Switch.............................................................................................................141 Parking Brake Switch................................................................................................................141 Rocker Switch.......................................................................................................................142 HYDRAULIC PUMP SOFT START (E100-120B Only) (72/80 Volt Only)............................................................................143 Electrical Warning Devices......................................................................................................................144 ELECTRICAL WARNING DEVICES..................................................................................................................144 GENERAL.................................................................................................................................144 DESCRIPTION.............................................................................................................................144 Operator Controlled Horns...........................................................................................................144 System Warning Lights, Buzzers and Bells............................................................................................144 Reverse Warning Horns...............................................................................................................145 Warning Lights......................................................................................................................145 REPLACEMENT.............................................................................................................................146 General.............................................................................................................................146 Replacing Horns or Bells............................................................................................................146 Replacing Horn Relay or Buzzer......................................................................................................146 Replacing Warning Lights............................................................................................................146 Light Assemblies....................................................................................................................147 Replacing Flashing Units............................................................................................................147 EV-1 Motor Controller Troubleshooting & Repair..................................................................................................148 INTRODUCTION................................................................................................................................148 GENERAL.................................................................................................................................148 SRO CIRCUIT AND PMT CIRCUIT.................................................................................................................149 STATIC RETURN TO OFF(SRO) CIRCUIT.......................................................................................................149 PULSE MONITOR TRIP (PMT)................................................................................................................149 THE SEQUENCE OF OPERATION...............................................................................................................150 TROUBLESHOOTING.............................................................................................................................150 GENERAL PROCEDURES......................................................................................................................150 FAULT IN THE CONTROL CIRCUIT........................................................................................................153 CHECKS AND REPAIRS..........................................................................................................................168 GENERAL.................................................................................................................................168 CHECK FOR THE CORRECT OPERATION.........................................................................................................168 CONTROL AND POWER FUSES.................................................................................................................169 CONTROL CARD............................................................................................................................169 Removal.............................................................................................................................171 Installation........................................................................................................................171 SCRs....................................................................................................................................171 An SCR "QUICK REF"..................................................................................................................171 Checking An SCR.....................................................................................................................171 The SCR 1 Assembly..................................................................................................................173 Thermal Sensor......................................................................................................................173 Checking SCR 1......................................................................................................................173 Replacing The SCR 1 Assembly........................................................................................................173 THE INDUCTOR AND CAPACITOR ASSEMBLY (THE "OFF" CIRCUIT FOR SCR 1).......................................................................174 Checking The Transformer and Inductor Assembly......................................................................................174 Checking the Supressors for the SCR 2 and SCR 5.....................................................................................174 Checking the SCR 2 and SCR 5........................................................................................................175 Replacing the SCR 2 and SCR 5.......................................................................................................175 Checking The Capacitor C1...........................................................................................................175 D3 And D4 Heat Sink Assembly........................................................................................................175 Checking The Diodes D3 and D4.......................................................................................................175 Replacing The Diodes D3 and D4......................................................................................................176 MOTOR CURRENT SENSOR....................................................................................................................176 THE ELECTRONIC DRIVER MODULE............................................................................................................176 CONTACTORS..............................................................................................................................177 "FORWARD" And "REVERSE" Contactors..................................................................................................177 CONTACTOR REPAIR........................................................................................................................178 Remove A Contactor Assembly.........................................................................................................178 Contactor Contacts..................................................................................................................178 Coil................................................................................................................................178 CHECK THE PMT CIRCUIT...................................................................................................................179 EV-1 Motor Controller-DESCR & OPER..............................................................................................................181 INTRODUCTION................................................................................................................................181 GENERAL.................................................................................................................................181 PRINCIPLES OF OPERATION.....................................................................................................................181 LIFT TRUCK CONTROL......................................................................................................................181 ELECTRONIC SPEED CONTROLS...............................................................................................................182 The Silicon Controlled Rectifier (SCR)..............................................................................................182 The Traction Circuit That Operates With Pulses......................................................................................182 The SCR 1 OFF Circuit...............................................................................................................186 THE CONTROL CARD FOR THE TRACTION CIRCUIT...............................................................................................186 SRO Circuit.........................................................................................................................187 Pulse Monitor Trip (PMT)............................................................................................................187 Control Card Adjustments............................................................................................................188 C/L (Current Limit).................................................................................................................188 Plug................................................................................................................................188 Creep...............................................................................................................................189 C/A (Controlled Acceleration).......................................................................................................189 THERMAL PROTECTION......................................................................................................................189 THE 1A CIRCUIT..........................................................................................................................189 FIELD WEAKENING.........................................................................................................................190 RAMP START..............................................................................................................................191 ACCELERATOR CONTROL.....................................................................................................................191 CONTACTORS AND ELECTRONIC DRIVERS.......................................................................................................191 The Electronic Drivers..............................................................................................................191 Contactors..........................................................................................................................191 CIRCUIT PROTECTION......................................................................................................................193 Current Limit.......................................................................................................................193 Thermal Protection..................................................................................................................193 Traction Circuit Fuse...............................................................................................................193 SEQUENCE OF OPERATION...................................................................................................................193 EV-1W Motor Controller Repair...................................................................................................................204 INTRODUCTION................................................................................................................................204 GENERAL.................................................................................................................................204 CONTROL FUNCTIONS AND ADJUSTMENTS...........................................................................................................205 OSCILLATOR CIRCUIT......................................................................................................................205 CONTROL CARD ADJUSTMENTS................................................................................................................205 Creep...............................................................................................................................205 C/A (Controlled Acceleration).......................................................................................................205 C/L (Current Limit).................................................................................................................205 1A Time.............................................................................................................................206 Plug................................................................................................................................206 Regenerative Braking................................................................................................................207 Field Weakening.....................................................................................................................207 Ramp Start..........................................................................................................................208 PULSE MONITOR TRIP (PMT)................................................................................................................209 SRO CIRCUIT.............................................................................................................................209 THE SEQUENCE OF OPERATION...............................................................................................................209 CHECKING FOR THE CORRECT OPERATION......................................................................................................209 TROUBLESHOOTING.............................................................................................................................211 GENERAL PROCEDURES......................................................................................................................211 EV-1W Motor Control Adjustments.....................................................................................................213 Fault Number 1. Regenerative Braking Contactor Does Not Close. The "Forward" and "Reverse" Contactors Will Close. The Lift Truck....214 Fault Number 2. Lift Truck Will Not Move In Either Direction. The Direction Contactors Never Close. The Regenerative Braking Con....215 Fault Number 3. Lift Truck Will Not Move In Either Direction. The Regenerative Braking Contactor Closes. A Direction Contactor C....218 Fault Number 4. Lift Truck Will Not Move In Either Direction. The Regenerative Braking Contactor Closes. The Direction Contactor....220 Fault Number 5. Lift Truck Will Move In Only One Direction. The Regenerative Braking Contactor Closes Normally. Direction Contac....222 Fault Number 6. One Direction Contactor Will Not Close. The Regenerative Braking Contactor Closes Normally. The Traction Circuit....222 Fault Number 7. Direction Contactors Close Normally. The Lift Truck Has Only Low Power Or Moves Slowly. The Regenerative Breakin....223 Fault Number 8. Contactor 1a Will Not Energize. The Other Operations Of The Lift Truck Are Normal...................................225 Fault Number 9. The Field Weakening Contactor Will Not Energize (36-48 Volt Lift Trucks Only). The Other Operations Of The Lift ....227 Fault Number 10. Regenerative Braking And Plugging Problems.........................................................................228 CHECKS AND REPAIRS..........................................................................................................................229 GENERAL.................................................................................................................................229 CONTROL AND POWER FUSES.................................................................................................................229 CONTROL CARD............................................................................................................................229 Removal.............................................................................................................................229 Installation........................................................................................................................229 SCRs....................................................................................................................................231 An SCR ''Quick Check''..............................................................................................................231 Checking An SCR.....................................................................................................................231 The SCR 1 Assembly..................................................................................................................232 Thermal Sensor......................................................................................................................232 Checking SCR 1......................................................................................................................232 Replacing The SCR 1 Assembly........................................................................................................233 THE INDUCTOR AND CAPACITOR ASSEMBLY (THE ''OFF'' CIRCUIT FOR SCR 1).....................................................................233 Checking The Transformer and Inductor Assembly......................................................................................234 Checking the SCR 2 and SCR 5........................................................................................................234 Checking the Suppressers for the SCR 2 and SCR 5....................................................................................234 Replacing the SCR 2 and SCR5........................................................................................................234 Checking The Capacitor C1...........................................................................................................234 D3 And D4 Heat Sink Assembly........................................................................................................235 Checking The Diodes D3 and D4.......................................................................................................235 Replacing The Diodes D3 and D4......................................................................................................235 MOTOR CURRENT SENSOR....................................................................................................................235 THE ELECTRONIC DRIVER MODULE............................................................................................................235 FORWARD AND REVERSE CONTACTORS..........................................................................................................236 CONTACTOR REPAIR........................................................................................................................236 Removing A Contactor Assembly.......................................................................................................237 Contactor Contacts..................................................................................................................237 Coil................................................................................................................................237 HYDRAULIC PUMP SOFT START...............................................................................................................237 SCHEMATIC DIAGRAM, 36-48 VOLT LIFT TRUCKS...............................................................................................240 WIRING DIAGRAM, 36-48 VOLT LIFT TRUCKS..................................................................................................242 SCHEMATIC DIAGRAM, 72-80 VOLT LIFT TRUCKS...............................................................................................244 WIRING DIAGRAM, 72-80 VOLT LIFT TRUCKS..................................................................................................246 Frame...........................................................................................................................................247 INTRODUCTION................................................................................................................................247 GENERAL.................................................................................................................................247 DESCRIPTION.............................................................................................................................247 DISASSEMBLY AND ASSEMBLY....................................................................................................................248 OVERHEAD GUARD..........................................................................................................................248 Removal.............................................................................................................................248 Installation........................................................................................................................248 SEAT ASSEMBLY...........................................................................................................................248 COUNTERWEIGHT...........................................................................................................................248 Removal.............................................................................................................................249 Installation........................................................................................................................249 HYDRAULIC TANK REPAIRS..................................................................................................................249 Small Leaks.........................................................................................................................249 Large Leaks.........................................................................................................................250 Steam Method Of Cleaning............................................................................................................250 Chemical Solution Method of Cleaning................................................................................................250 Other Methods.......................................................................................................................250 LABEL REPLACEMENT.......................................................................................................................251 Hydraulic Gear Pump.............................................................................................................................253 INTRODUCTION................................................................................................................................253 DESCRIPTION.............................................................................................................................253 OPERATION...............................................................................................................................253 Flow Control Valve..................................................................................................................255 Relief Valve........................................................................................................................255 REPAIRS.....................................................................................................................................256 REMOVAL.................................................................................................................................256 DISASSEMBLY.............................................................................................................................256 CLEANING................................................................................................................................258 INSPECTION..............................................................................................................................258 ASSEMBLY................................................................................................................................259 INSTALLATION............................................................................................................................260 CHECKS AND ADUSTMENTS.......................................................................................................................261 CHECK THE OUTPUT OF THE PUMP............................................................................................................261 CHECK FOR AIR IN THE HYDRAULIC SYSTEM...................................................................................................261 TROUBLESHOOTING.............................................................................................................................263 Hydraulic System................................................................................................................................266 INTRODUCTION................................................................................................................................266 General.................................................................................................................................266 Description.............................................................................................................................266 The Control Valve.......................................................................................................................268 REPAIRS.....................................................................................................................................273 Hydraulic Pump..........................................................................................................................273 Main Control Valve......................................................................................................................275 Hydraulic Pump Contactor................................................................................................................280 Contactor Repair........................................................................................................................280 CHECKS AND ADJUSTMENTS......................................................................................................................281 Adjusting The Pressure Relief Valve.....................................................................................................281 Adjustment Of The Control Linkage.......................................................................................................281 Hydraulic Pump Switch...................................................................................................................281 TROUBLESHOOTING.............................................................................................................................282 Hydraulic Vane Pump.............................................................................................................................284 INTRODUCTION................................................................................................................................284 GENERAL.................................................................................................................................284 DESCRIPTION.............................................................................................................................284 OPERATION...............................................................................................................................284 Pump................................................................................................................................284 Relief Valve........................................................................................................................285 REPAIRS.....................................................................................................................................286 REMOVAL.................................................................................................................................286 DISASSEMBLY.............................................................................................................................286 ASSEMBLY................................................................................................................................287 INSTALLATION............................................................................................................................288 CHECKS AND ADJUSTMENTS......................................................................................................................288 CHECKING THE RELIEF PRESSURE OF THE RELIEF VALVE........................................................................................288 Lift Trucks With Internal Combustion Engines........................................................................................288 Electric Lift Trucks................................................................................................................288 Electric Lift Trucks With Adjustable Relief Valve...................................................................................289 SPECIFICATIONS..............................................................................................................................290 TROUBLESHOOTING.............................................................................................................................290 Industrical Battery.............................................................................................................................291 INTRODUCTION................................................................................................................................291 GENERAL.................................................................................................................................291 LEAD-ACID BATTERIES.....................................................................................................................291 SPECIFIC GRAVITY........................................................................................................................292 CHEMICAL REACTION IN A CELL.............................................................................................................292 ELECTRICAL TERMS........................................................................................................................293 HOW TO SELECT THE BATTERY...............................................................................................................293 VOLTAGE OF A BATTERY....................................................................................................................293 THE BATTERY AS A COUNTERWEIGHT..........................................................................................................294 BATTERY RATINGS.........................................................................................................................294 Kilowatt-Hours......................................................................................................................295 BATTERY MAINTENANCE.........................................................................................................................295 SAFETY PROCEDURES.......................................................................................................................295 MAINTENCE RECORDS.......................................................................................................................296 THE NEW BATTERY.........................................................................................................................296 HOW TO CLEAN THE BATTERY................................................................................................................297 HOW TO ADD WATER........................................................................................................................297 THE HYDROMETER..........................................................................................................................298 BATTERY TEMPERATURE.....................................................................................................................298 CHARGING THE BATTERY....................................................................................................................299 Types Of Battery Charges............................................................................................................300 Methods Of Charging.................................................................................................................301 Troubleshooting The Charger.........................................................................................................301 How to Know When The Battery Is Fully Charged.......................................................................................302 WHERE TO CHARGE THE BATTERIES...........................................................................................................302 Equipment Needed....................................................................................................................302 BATTERY CONNECTORS......................................................................................................................303 BATTERY CARE............................................................................................................................303 Lift Cylinders..................................................................................................................................305 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST................................................................................................305 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................................305 LIFT CYLINDERS..............................................................................................................................308 GENERAL.................................................................................................................................308 DESCRIPTION.............................................................................................................................308 Lowering Control Valve..............................................................................................................308 Cylinders (General).................................................................................................................311 Cylinders (H520-620B,H700-800A).....................................................................................................313 Cylinders (H360-460B)...............................................................................................................314 Cylinders (Two-Speed)...............................................................................................................314 REPAIRS.....................................................................................................................................315 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..................................................................................315 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................................315 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.............................................................319 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.......................................................317 DISASSEMBLY.............................................................................................................................317 ASSEMBLY................................................................................................................................319 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...........................................................................................319 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................................319 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead....................................................319 CHEVRON PACKING.........................................................................................................................320 LIFT CYLINDERS FOR VISTA MASTS..............................................................................................................323 DESCRIPTION.............................................................................................................................323 Lowering Control Valve..............................................................................................................325 REMOVAL.................................................................................................................................326 DISASSEMBLY.............................................................................................................................326 ASSEMBLY................................................................................................................................326 INSTALLATION............................................................................................................................327 Main Lift Cylinders.................................................................................................................327 Free-Lift Cylinders.................................................................................................................327 CHECKS AND ADJUSTMENTS......................................................................................................................328 CHECK FOR LEAKS IN LIFT SYSTEM..........................................................................................................328 TROUBLESHOOTING.............................................................................................................................329 SPECIFICATIONS..............................................................................................................................330 Mast Description................................................................................................................................331 INTRODUCTION................................................................................................................................331 GENERAL.................................................................................................................................331 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.).......................................................................333 FULL FREE-LIFT MASTS....................................................................................................................333 THREE-STAGE MASTS.......................................................................................................................335 FOUR-STAGE MASTS........................................................................................................................336 SEQUENCE VALVE..........................................................................................................................336 Mast Repair.....................................................................................................................................338 INTRODUCTION................................................................................................................................338 GENERAL.................................................................................................................................338 REPAIRS.....................................................................................................................................338 FORKS...................................................................................................................................338 CARRIAGE................................................................................................................................338 Removal.............................................................................................................................338 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................................339 Installation........................................................................................................................340 MASTS...................................................................................................................................342 Removal.............................................................................................................................342 Disassembly.........................................................................................................................344 Cleaning and Inspection.............................................................................................................348 Assembly............................................................................................................................349 INSTALLATION............................................................................................................................350 CHECKS AND ADJUSTMENTS......................................................................................................................350 CHECKING FOR LEAKS IN THE LIFT SYSTEM...................................................................................................350 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE..........................................................................351 LIFT CHAIN ADJUSTMENTS..................................................................................................................351 MAST ADJUSTMENTS........................................................................................................................352 Guide Shoe Adjustment...............................................................................................................353 CARRIAGE ADJUSTMENT.....................................................................................................................355 TROUBLESHOOTING.............................................................................................................................357 Master Cylinder.................................................................................................................................358 INTRODUCTION................................................................................................................................358 GENERAL.................................................................................................................................358 DESCRIPTION.............................................................................................................................358 REPAIRS.....................................................................................................................................358 REMOVAL AND DISASSEMBLY.................................................................................................................358 CLEANING ...............................................................................................................................359 ASSEMBLY................................................................................................................................359 CHECKS AND ADJUSTMENTS......................................................................................................................359 CHECKS..................................................................................................................................359 Parking Brake...................................................................................................................................360 INTRODUCTION................................................................................................................................360 General.................................................................................................................................360 Description.............................................................................................................................360 REPAIRS.....................................................................................................................................361 Parking Brake Assembly..................................................................................................................361 ADJUSTMENTS.................................................................................................................................362 Adjustment of the Hand Brake Linkage....................................................................................................362 Adjustment of the Linkage for the Hand and Seat Brake...................................................................................362 Periodic Maintenance............................................................................................................................363 INTRODUCTION................................................................................................................................363 General.................................................................................................................................363 Moving A Disabled Lift Truck............................................................................................................363 MAINTENANCE SCHEDULE........................................................................................................................363 MAINTENANCE PROCEDURES......................................................................................................................365 Every 8 Hours or Daily..................................................................................................................365 Hydraulic System....................................................................................................................365 Battery.............................................................................................................................366 Tires...............................................................................................................................366 Lift Mechanism......................................................................................................................366 Forks...............................................................................................................................366 Lift Chain..........................................................................................................................367 Upright.............................................................................................................................367 Carriage............................................................................................................................368 Load Backrest Extension.............................................................................................................368 Brakes..............................................................................................................................368 Gauges and Horn.....................................................................................................................369 Every 350 Hours or Two Months...........................................................................................................369 Brake Fluid.........................................................................................................................369 Hydraulic Tank Breather.............................................................................................................370 Differential and Speed Reducer......................................................................................................370 Uprights............................................................................................................................370 Forks...............................................................................................................................370 Electrical Inspection...............................................................................................................372 Every 2000 Hours or Yearly..............................................................................................................374 Hydraulic System....................................................................................................................374 Wheel Bearings......................................................................................................................375 Brake Shoes.........................................................................................................................375 WHEELS AND TIRES............................................................................................................................375 CHANGING TIRES..............................................................................................................................375 BATTERY.....................................................................................................................................376 CHANGING THE BATTERY....................................................................................................................377 SAE & Metric Fasteners..........................................................................................................................379 INTRODUCTION................................................................................................................................379 NOMENCLATURE, THREADS...................................................................................................................379 STRENGTH IDENTIFICATION.................................................................................................................380 TABLE 1. BOLTS AND SCREWS...................................................................................................................380 TABLE 2. STUDS AND NUTS.....................................................................................................................381 TABLE 3. TORQUE NUTS........................................................................................................................382 TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................................383 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................................384 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................................385 SPD Reducer & Differential......................................................................................................................388 INTRODUCTION................................................................................................................................388 General.................................................................................................................................388 Description.............................................................................................................................388 REPAIRS.....................................................................................................................................389 Removal Of The Speed Reducer And Differential...........................................................................................389 Disassembly.............................................................................................................................390 Assembly................................................................................................................................391 Installation Of The Drive Assembly......................................................................................................395 TROUBLESHOOTING.............................................................................................................................395 Steering Axle...................................................................................................................................397 INTRODUCTION................................................................................................................................397 GENERAL.................................................................................................................................397 DESCRIPTION.............................................................................................................................397 REPAIRS.....................................................................................................................................398 STEERING AXLES WITH STUB SHAFT MOUNTS...................................................................................................398 Removal.............................................................................................................................399 Installation........................................................................................................................399 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS..................................................................................................400 Removal.............................................................................................................................400 Installation........................................................................................................................401 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)...............................................................402 Removal.............................................................................................................................402 Installation........................................................................................................................403 WHEELS AND HUBS.........................................................................................................................403 Removal and Disassembly.............................................................................................................403 Cleaning............................................................................................................................403 Assembly And Installation...........................................................................................................403 SPINDLES, BEARING AND TIE RODS..........................................................................................................403 Removal And Disassembly.............................................................................................................403 Cleaning............................................................................................................................403 Assembly And Installation...........................................................................................................403 STEERING CYLINDER.......................................................................................................................405 Removal And Disassembly.............................................................................................................405 Cleaning............................................................................................................................406 Assembly And Installation...........................................................................................................406 CHECKS AND ADJUSTMENTS......................................................................................................................408 STEERING CYLINDER.......................................................................................................................408 CENTER PIVOT OR RUBBER MOUNTS...........................................................................................................408 SPINDLE AND HUB.........................................................................................................................408 TROUBLESHOOTING.............................................................................................................................409 Steering Control Unit...........................................................................................................................410 INTRODUCTION................................................................................................................................410 GENERAL.................................................................................................................................410 DESCRIPTION.............................................................................................................................410 OPERATION...............................................................................................................................410 REPAIRS.....................................................................................................................................410 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................410 TYPE "A" STEERING COLUMN ASSEMBLY.......................................................................................................412 Removal And Disassembly.............................................................................................................412 Assembly And Installation...........................................................................................................412 TYPE "A" STEERING COLUMN................................................................................................................413 TYPE "A" STEERING COLUMN................................................................................................................414 TYPE "B" STEERING COLUMN................................................................................................................415 Removal And Disassembly.............................................................................................................415 Assembly And Installation...........................................................................................................415 TYPE "B" STEERING COLUMN................................................................................................................416 Disassembly of Steering Control Unit................................................................................................417 Cleaning of Steering Control Unit...................................................................................................417 Assembly of Steering Control Unit...................................................................................................419 CHECKS AND ADJUSTMENTS......................................................................................................................422 REMOVE AIR FROM THE SYSTEM..............................................................................................................422 TROUBLESHOOTING.............................................................................................................................423 Tilt Cylinder...................................................................................................................................424 INTRODUCTION................................................................................................................................424 GENERAL.................................................................................................................................424 DESCRIPTION.............................................................................................................................424 REPAIRS.....................................................................................................................................424 REMOVAL.................................................................................................................................424 DISASSEMBLY.............................................................................................................................424 CLEANING................................................................................................................................424 ASSEMBLY................................................................................................................................424 Tilt Cylinders with O-Rings or Single Lip Seals.....................................................................................424 Tilt Cylinders for the XM and XMS Models............................................................................................425 Tilt Cylinders for H700 800A and Early Model H700 920B..............................................................................427 INSTALLATION............................................................................................................................427 Tilt Cylinders Using Chevron Packing................................................................................................428 CHECKS AND ADJUSTMENTS......................................................................................................................430 CHECK THE TILT CYLINDERS FOR LEAKS......................................................................................................430 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.................................................................................430 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS....................................................................................431 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS...................................................................................432 TROUBLESHOOTING.............................................................................................................................434 Vista Mast Description..........................................................................................................................435 INTRODUCTION................................................................................................................................435 GENERAL.................................................................................................................................435 VISTA TWO-STAGE MASTS.......................................................................................................................437 DESCRIPTION.............................................................................................................................437 OPERATION...............................................................................................................................440 VISTA THREE-STAGE MASTS.....................................................................................................................440 DESCRIPTION.............................................................................................................................440 OPERATION...............................................................................................................................442 SEQUENCE VALVE..........................................................................................................................444 Vista Mast Repair...............................................................................................................................447 INTRODUCTION................................................................................................................................447 GENERAL.................................................................................................................................447 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST................................................................................................447 REPAIRS.....................................................................................................................................448 FORKS...................................................................................................................................448 Removal.............................................................................................................................448 CARRIAGE................................................................................................................................448 Removal (Two-Stage and Later Production Three-Stage Carriages)......................................................................448 Removal (Carriages with Removable Stop Block).......................................................................................449 Installation (Two-Stage and Later Production Three-Stage Carriages).................................................................450 Installation (Carriages With Removable Stop Block)..................................................................................450 TWO-STAGE MASTS.............................................................................................................................452 REMOVAL.................................................................................................................................452 DISASSEMBLY.............................................................................................................................453 CLEANING AND INSPECTION.................................................................................................................454 ASSEMBLY................................................................................................................................455 INSTALLATION............................................................................................................................456 THREE-STAGE MASTS...........................................................................................................................456 REMOVAL.................................................................................................................................456 DISASSEMBLY.............................................................................................................................456 CLEANING AND INSPECTION.................................................................................................................458 ASSEMBLY................................................................................................................................458 INSTALLATION............................................................................................................................459 LIFT AND TILT CYLINDERS.................................................................................................................460 SIDE SHIFT CARRIAGE.....................................................................................................................460 Removal.............................................................................................................................460 Repairs.............................................................................................................................460 Installation........................................................................................................................460 SEQUENCE VALVE..........................................................................................................................461 Removal and Disassembly.............................................................................................................464 Cleaning............................................................................................................................464 Assembly and Installation...........................................................................................................464 CHECKS AND ADJUSTMENTS......................................................................................................................465 CHECKING FOR LEAKS IN THE LIFT SYSTEM...................................................................................................465 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE..........................................................................465 LIFTING CHAIN ADJUSTMENTS...............................................................................................................466 MAST ADJUSTMENTS........................................................................................................................467 CARRIAGE ADJUSTMENT.....................................................................................................................468 HEADER HOSE ROLLER ADJUSTMENT, 2-STAGE..................................................................................................469 TROUBLESHOOTING.............................................................................................................................470 TORQUE SPECIFICATIONS.......................................................................................................................471 VISTA MASTS.................................................................................................................................472
HYSTER B108 (E30-50B, E60BS, E60-120B) SERVICE MANUAL – PDF DOWNLOAD:
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