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Hyster D118 (R30E,EA R30EF R35E) Service Manual – PDF DOWNLOAD
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Description
Hyster D118 (R30E,EA R30EF R35E) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster D118 (R30E,EA R30EF R35E) Service Manual – PDF DOWNLOAD
Language : English
Pages : 569
Downloadable : Yes
File Type : PDF
Size: 34.1 MB
TABLE OF CONTENTS:
Hyster D118 (R30E,EA R30EF R35E) Service Manual – PDF DOWNLOAD
battery indicators........................................................................................... 1 INTRODUCTION............................................................................................. 3 GENERAL.............................................................................................. 3 INDICATORS WITH METER MOVEMENT....................................................................... 4 BATTERY INDICATORS WITH LCD OR LED DISPLAYS.......................................................... 5 Liquid Crystal Displays.......................................................................... 5 Description, Sem Display Panel................................................................... 8 Light Emitting Diode Displays.................................................................... 9 Description LX Series............................................................................ 9 Description, ZX Series Display Panels............................................................ 10 CHECKS AND ADJUSTMENTS................................................................................... 11 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS.............................................. 11 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS................................................. 11 Reset Potentiometer.............................................................................. 12 Specific Gravity Alarm........................................................................... 12 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS.............................................. 13 BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS................................................. 13 Reset Potentiometer.............................................................................. 13 Discharge Potentiometer.......................................................................... 14 LED DISPLAY WITH LIFT INTERRUPT...................................................................... 14 CHECKING CURTIS 933-1 METER.......................................................................... 14 Reset Check...................................................................................... 15 Discharge Check.................................................................................. 15 Lockout Check.................................................................................... 16 LED's Do Not Illuminate.......................................................................... 16 Hour Glass Icon.................................................................................. 16 ADJUSTMENT OF CURTIS 933-1 METER..................................................................... 16 ADJUSTMENT OF SEVCON POWERGAUGE...................................................................... 17 CURTIS DASH DISPLAY ASSEMBLY............................................................................. 17 Description/Features................................................................................. 17 Operation............................................................................................ 18 Testing.............................................................................................. 18 Inoperative Dash Display Assembly................................................................ 18 Inoperative drive Mode Selection................................................................. 18 Troubleshooting With a Programmer Hand Set....................................................... 19 Troubleshooting Without a Programmer Hand Set.................................................... 19 No Warnings Or Faults Displayed.................................................................. 20 MIB/Dash Display Communication................................................................... 21 Lift Interrupt................................................................................... 21 Lost MIB Signal Displayed........................................................................ 22 Lift Pump Hourmeter Input........................................................................ 22 Forward/Reverse Hourmeter Inputs................................................................. 22 Removal.......................................................................................... 22 Installation..................................................................................... 23 Adjustment (Set-up).............................................................................. 23 REPAIRS.................................................................................................. 24 BATTERY INDICATORS................................................................................... 24 Replacement...................................................................................... 24 CONTROLLER FOR THE BATTERY INDICATOR................................................................. 24 Replacement...................................................................................... 24 DISPLAY PANEL COMPONENTS............................................................................. 24 REPLACING SEM DISPLAY PANEL.......................................................................... 25 SEM DISPLAY PANEL REMOVAL............................................................................ 25 Removal And Replacement.......................................................................... 25 brake assembly............................................................................................... 29 INTRODUCTION............................................................................................. 29 GENERAL.............................................................................................. 29 DESCRIPTION AND OPERATION............................................................................ 29 Electric Brake................................................................................... 29 Brake Switch..................................................................................... 29 REPAIRS.................................................................................................. 30 ELECTRIC BRAKE....................................................................................... 30 Removal and Disassembly.......................................................................... 30 R25A, R30C, R30CA, R30CH, R30DH, N30-50CA, N30-40CR.............................................. 30 R30E, R30EA, (See Figure 38.).................................................................... 30 Assembly and Installation........................................................................ 31 R25A, R30C, R30CA, R30CH, R30DH, N30-50CA, N30-40CR.............................................. 31 R30E, R30EA...................................................................................... 31 BRAKE SWITCH......................................................................................... 31 TROUBLESHOOTING.......................................................................................... 32 capacities and specifications................................................................................ 33 BATTERY SPECIFICATIONS................................................................................... 33 TRANSISTOR CONTROLLER ADJUSTMENT POINTS.................................................................. 33 EV–100 TRACTION CARD SETTINGS............................................................................ 33 MASTER DRIVE UNIT........................................................................................ 33 SYSTEM II ELECTRONIC CONTROL MODULE (ELECTRIC POWER STEERING)............................................ 34 TERMINAL AND PIN ARRANGEMENTS FOR THE EV–100 CONTROL CARD................................................ 35 TERMINAL AND PIN ARRANGEMENTS FOR THE CURTIS 1204X – 4406................................................ 36 SYSTEM II ELECTRONIC CONTROL MODULE (WIRE GUIDANCE)...................................................... 37 TRANSISTOR RESISTANCE.................................................................................... 37 SYSTEM II WIRE GUIDANCE SPECIFICATIONS................................................................... 38 HYDRAULIC SYSTEM......................................................................................... 39 TORQUE SPECIFICATIONS.................................................................................... 39 DC Motor Maintenance......................................................................................... 41 toc...................................................................................................... 41 DC Motor Maintenance................................................................................. 41 General.............................................................................................. 43 Brush and Commutator Inspection...................................................................... 43 Hydraulic Pump Motor and Traction Motor.......................................................... 43 Steering Pump Motor.............................................................................. 46 Normal Commutator Surface........................................................................ 46 Commutator Problems.............................................................................. 46 Brush Replacement.................................................................................... 50 Stoning the Commutator............................................................................... 52 Motors Repair........................................................................................ 54 Disassemble...................................................................................... 54 Traction Motor and Hydraulic Pump Motor...................................................... 54 Steering Pump Motor.......................................................................... 58 Assemble......................................................................................... 58 Traction Motor and Hydraulic Pump Motor...................................................... 58 Steering Pump Motor.......................................................................... 59 Brush Alignment, Traction and Hydraulic Motors....................................................... 62 Tests for Damaged Field and Armature................................................................. 62 Test for an Open Circuit in Armature............................................................. 62 Test for Short Circuit in One Armature Winding................................................... 63 Test for Short Circuit to Armature Shaft......................................................... 63 Test for Open Circuit in Field Coil.............................................................. 63 Test for Short Circuit in Field Coil............................................................. 63 Test for Short Circuit between Field and Motor Case.............................................. 64 Brush Holder Test................................................................................ 64 Troubleshooting...................................................................................... 64 tables................................................................................................... 41 Table 1. Normal Commutator Surfaces.................................................................. 45 Table 2. Commutator Problems......................................................................... 46 Table 3. Brush Wear Replacement Guide................................................................ 50 electric power steering...................................................................................... 68 ......................................................................................................... 68 ......................................................................................................... 69 ......................................................................................................... 70 ......................................................................................................... 71 ......................................................................................................... 72 ......................................................................................................... 73 ......................................................................................................... 74 ......................................................................................................... 75 ......................................................................................................... 76 ......................................................................................................... 77 ......................................................................................................... 78 ......................................................................................................... 79 ......................................................................................................... 80 ......................................................................................................... 81 ......................................................................................................... 82 ......................................................................................................... 83 ......................................................................................................... 84 ......................................................................................................... 85 ......................................................................................................... 86 ......................................................................................................... 87 electrical checks and adjustments............................................................................ 88 CHECKS AND ADJUSTMENTS................................................................................... 88 GENERAL.............................................................................................. 88 CONTROL AND POWER FUSES.............................................................................. 88 EV-100 MOTOR CONTROLLER.............................................................................. 89 EV-100 Traction Control Card..................................................................... 89 Adjust Creep Speed, "CREEP".................................................................. 89 Adjust Controlled Acceleration, "C/A"........................................................ 89 Adjust Current Limit, "C/L".................................................................. 89 ACCELERATOR POTENTIOMETER............................................................................ 90 FORWARD AND REVERSE SWITCHES......................................................................... 92 LIMIT SWITCH LS-1 AND LS-3 (Traction Cutout And Traction Override)................................... 92 LOOSE CHAIN SWITCH................................................................................... 92 LIMIT SWITCH LS-2 (Lowering Speed, Travel Speed)..................................................... 93 REPAIR................................................................................................... 93 GENERAL.............................................................................................. 93 REPLACE THE ELECTRICAL PARTS OF THE STEERING, HYDRAULIC OR OPTIONAL GUIDANCE SYSTEMS................. 94 REPLACE THE ACCELERATOR POTENTIOMETER................................................................ 94 REPLACE THE KEY AND OTHER CONSOLE SWITCHES AND INDICATOR LIGHTS...................................... 94 REPLACE SWITCHES IN THE DIRECTION/SPEED CONTROL...................................................... 95 Replace The Foot Switch.......................................................................... 96 Replace Loose Chain Switch....................................................................... 96 REPLACE THE LIMIT SWITCHES........................................................................... 97 Limit Switch LS-1 (Upright)...................................................................... 97 Limit Switch LS-2 (Lowering Speed)............................................................... 98 ev-100 motor controller description and operation............................................................ 99 ......................................................................................................... 99 .........................................................................................................100 .........................................................................................................101 .........................................................................................................102 .........................................................................................................103 .........................................................................................................104 .........................................................................................................105 .........................................................................................................106 .........................................................................................................107 .........................................................................................................108 .........................................................................................................109 .........................................................................................................110 .........................................................................................................111 .........................................................................................................112 .........................................................................................................113 .........................................................................................................114 .........................................................................................................115 .........................................................................................................116 .........................................................................................................117 .........................................................................................................118 .........................................................................................................119 .........................................................................................................120 .........................................................................................................121 .........................................................................................................122 .........................................................................................................123 .........................................................................................................124 .........................................................................................................125 .........................................................................................................126 .........................................................................................................127 .........................................................................................................128 .........................................................................................................129 .........................................................................................................130 .........................................................................................................131 .........................................................................................................132 .........................................................................................................133 .........................................................................................................134 .........................................................................................................135 .........................................................................................................136 .........................................................................................................137 .........................................................................................................138 ev-100 motor controller repairs and adjustments..............................................................139 .........................................................................................................139 .........................................................................................................140 .........................................................................................................141 .........................................................................................................142 .........................................................................................................143 .........................................................................................................144 .........................................................................................................145 .........................................................................................................146 .........................................................................................................147 .........................................................................................................148 .........................................................................................................149 .........................................................................................................150 .........................................................................................................151 .........................................................................................................152 .........................................................................................................153 .........................................................................................................154 .........................................................................................................155 .........................................................................................................156 .........................................................................................................157 .........................................................................................................158 .........................................................................................................159 .........................................................................................................160 .........................................................................................................161 .........................................................................................................162 .........................................................................................................163 .........................................................................................................164 .........................................................................................................165 .........................................................................................................166 ev-100 motor controller troubleshooting......................................................................167 .........................................................................................................167 .........................................................................................................168 .........................................................................................................169 .........................................................................................................170 .........................................................................................................171 .........................................................................................................172 .........................................................................................................173 .........................................................................................................174 .........................................................................................................175 .........................................................................................................176 .........................................................................................................177 .........................................................................................................178 .........................................................................................................179 .........................................................................................................180 .........................................................................................................181 .........................................................................................................182 .........................................................................................................183 .........................................................................................................184 .........................................................................................................185 .........................................................................................................186 .........................................................................................................187 .........................................................................................................188 .........................................................................................................189 .........................................................................................................190 .........................................................................................................191 .........................................................................................................192 .........................................................................................................193 .........................................................................................................194 .........................................................................................................195 .........................................................................................................196 .........................................................................................................197 .........................................................................................................198 .........................................................................................................199 .........................................................................................................200 .........................................................................................................201 .........................................................................................................202 .........................................................................................................203 .........................................................................................................204 .........................................................................................................205 .........................................................................................................206 .........................................................................................................207 .........................................................................................................208 ev-100lxt lx lxp lxd ev-200lxt lx motor controller and diagnostic hand set...................................209 .........................................................................................................209 .........................................................................................................210 .........................................................................................................211 .........................................................................................................212 .........................................................................................................213 .........................................................................................................214 .........................................................................................................215 .........................................................................................................216 .........................................................................................................217 .........................................................................................................218 .........................................................................................................219 .........................................................................................................220 .........................................................................................................221 .........................................................................................................222 .........................................................................................................223 .........................................................................................................224 .........................................................................................................225 .........................................................................................................226 .........................................................................................................227 .........................................................................................................228 .........................................................................................................229 .........................................................................................................230 .........................................................................................................231 .........................................................................................................232 .........................................................................................................233 .........................................................................................................234 .........................................................................................................235 .........................................................................................................236 .........................................................................................................237 .........................................................................................................238 .........................................................................................................239 .........................................................................................................240 .........................................................................................................241 .........................................................................................................242 .........................................................................................................243 .........................................................................................................244 .........................................................................................................245 .........................................................................................................246 .........................................................................................................247 .........................................................................................................248 .........................................................................................................249 .........................................................................................................250 .........................................................................................................251 .........................................................................................................252 .........................................................................................................253 .........................................................................................................254 .........................................................................................................255 .........................................................................................................256 .........................................................................................................257 .........................................................................................................258 .........................................................................................................259 .........................................................................................................260 .........................................................................................................261 .........................................................................................................262 .........................................................................................................263 .........................................................................................................264 .........................................................................................................265 .........................................................................................................266 .........................................................................................................267 .........................................................................................................268 .........................................................................................................269 .........................................................................................................270 .........................................................................................................271 .........................................................................................................272 .........................................................................................................273 .........................................................................................................274 .........................................................................................................275 .........................................................................................................276 .........................................................................................................277 .........................................................................................................278 .........................................................................................................279 .........................................................................................................280 .........................................................................................................281 .........................................................................................................282 .........................................................................................................283 .........................................................................................................284 .........................................................................................................285 .........................................................................................................286 .........................................................................................................287 .........................................................................................................288 .........................................................................................................289 .........................................................................................................290 .........................................................................................................291 .........................................................................................................292 .........................................................................................................293 .........................................................................................................294 .........................................................................................................295 .........................................................................................................296 frame........................................................................................................297 INTRODUCTION.............................................................................................297 General..............................................................................................297 Description..........................................................................................297 REPAIR...................................................................................................298 Removal And Disassembly..............................................................................298 Covers, Panels And Plates........................................................................298 R30EA-FS Caster And Caser Wheel..................................................................298 Description..................................................................................298 Replacing Caster.............................................................................299 Replacing Caster Wheels......................................................................299 Painting Instructions................................................................................299 Label Replacement....................................................................................299 gauges.......................................................................................................301 INTRODUCTION.............................................................................................301 GENERAL..............................................................................................301 DESCRIPTION..............................................................................................301 GENERAL..............................................................................................301 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................304 LED DISPLAY PANEL....................................................................................304 Battery Discharge Indicators.....................................................................304 Brush Wear Indicators............................................................................305 Motor Temperature Indicators.....................................................................306 "LX" SERIES DISPLAY PANEL............................................................................307 Hourmeter Functions..............................................................................308 Battery Indicator Function.......................................................................308 Status Code Function.............................................................................308 "ZX" SERIES DISPLAY PANELS...........................................................................308 Display Panel....................................................................................309 Basic Display Panels.............................................................................309 Performance Display..............................................................................311 Brush Wear Indicators............................................................................314 CHECKS AND ADJUSTMENTS...................................................................................314 GENERAL..............................................................................................314 REPLACEMENT..............................................................................................315 GENERAL..............................................................................................315 METER REPLACEMENT....................................................................................315 SENDER REPLACEMENT...................................................................................316 Fuel Level Sender................................................................................316 Pressure And Temperature Sender..................................................................316 I.T.W. DISPLAY PANEL.................................................................................317 Removal..........................................................................................317 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................318 Removal..........................................................................................318 Replacing Display Panel Assembly.................................................................318 Indicator LEDs...................................................................................318 Battery Indicators...............................................................................318 Digital Display (Performance Disply Panel Only)..................................................318 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....318 Replacing Parts Of The Basic Display Panel.......................................................319 Replacing Parts Of The Performance Display Panel.................................................321 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................321 Removal And Replacement..........................................................................321 SPECIFICATIONS...........................................................................................322 TROUBLESHOOTING..........................................................................................323 Gear pumps...................................................................................................324 INTRODUCTION.............................................................................................324 DESCRIPTION..........................................................................................324 OPERATION............................................................................................324 Flow Control Valve...............................................................................326 Relief Valve.....................................................................................326 REPAIRS..................................................................................................327 REMOVAL..............................................................................................327 DISASSEMBLY..........................................................................................327 CLEANING.............................................................................................329 INSPECTION...........................................................................................329 ASSEMBLY.............................................................................................330 INSTALLATION.........................................................................................331 CHECKS AND ADUSTMENTS....................................................................................332 CHECK THE OUTPUT OF THE PUMP.........................................................................332 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................332 TROUBLESHOOTING..........................................................................................334 hydraulic system.............................................................................................337 INTRODUCTION.............................................................................................337 Description..........................................................................................337 Hydraulic System.................................................................................337 Pump.............................................................................................338 Control Valve....................................................................................338 REPAIRS..................................................................................................341 Hydraulic Pump.......................................................................................341 Removal..........................................................................................341 Seal Replacement.................................................................................342 Installation.....................................................................................343 Control Valve........................................................................................343 Removal..........................................................................................343 Disassembly......................................................................................345 Cleaning and Inspection..........................................................................345 Assembly.........................................................................................345 Installation.....................................................................................346 CHECKS AND ADJUSTMENTS...................................................................................346 Relief Valve Adjustments.............................................................................346 TROUBLESHOOTING..........................................................................................347 Hydraulic Pump.......................................................................................347 Control Valve........................................................................................348 SPECIFICATIONS...........................................................................................349 large batteries..............................................................................................350 INTRODUCTION.............................................................................................350 GENERAL..............................................................................................350 LEAD-ACID BATTERIES..................................................................................350 SPECIFIC GRAVITY.....................................................................................350 THE CHEMICAL REACTION IN A CELL......................................................................351 ELECTRICAL TERMS.........................................................................................352 HOW TO SELECT THE BATTERY............................................................................352 VOLTAGE OF A BATTERY.................................................................................352 THE BATTERY AS A COUNTERWEIGHT.......................................................................353 BATTERY RATINGS......................................................................................353 Kilowatt-Hours...................................................................................354 BATTERY MAINTENANCE......................................................................................354 SAFETY PROCEDURES....................................................................................354 MAINTENACE RECORDS...................................................................................355 THE NEW BATTERY......................................................................................355 HOW TO CLEAN THE BATTERY.............................................................................356 HOW TO ADD WATER.....................................................................................356 THE HYDROMETER.......................................................................................357 BATTERY TEMPERATURE..................................................................................357 CHARGING THE BATTERY.................................................................................358 Types Of Battery Charges.........................................................................359 Methods Of Charging..............................................................................360 Troubleshooting The Charger......................................................................360 How To Know When The Battery Is Fully Charged....................................................361 WHERE TO CHARGE THE BATTERIES........................................................................361 Equipment Needed.................................................................................361 BATTERY CONNECTORS...................................................................................362 BATTERY CARE.........................................................................................362 lift cylinders...............................................................................................364 Safety Procedures When Working Near Mast.................................................................366 General..................................................................................................371 Description..............................................................................................371 Lowering Control Valve...............................................................................371 Cylinders (General)..................................................................................374 Cylinders (H520-620B, H700-800A).....................................................................374 Retainer, Install................................................................................374 Cylinders (H360-460B)................................................................................376 Cylinders (Two-Speed)................................................................................379 Lift Cylinder Repair.....................................................................................380 Lift Cylinder Removal Without Removing Mast..........................................................380 Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast....................380 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead.......................381 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder.........................382 Disasemble...........................................................................................382 Assemble.............................................................................................382 Lift Cylinder Installation in Mast...................................................................384 Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast.....................384 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead.......................384 Chevron-Style Packing................................................................................384 Chevron-Style Packing Installation on Piston.....................................................385 Chevron-Style Packing Installation in Packing Gland..............................................387 Lift Cylinders for Vista Masts...........................................................................388 Description..........................................................................................388 Lowering Control Valve...........................................................................388 Remove...............................................................................................390 Disassemble..........................................................................................391 Assemble.............................................................................................392 Install..............................................................................................393 Main Lift Cylinders..............................................................................393 Free-Lift Cylinder...............................................................................393 Lift System Leak Check...................................................................................393 Specifications...........................................................................................394 Troubleshooting..........................................................................................395 maintenance schedule.........................................................................................398 INTRODUCTION.............................................................................................398 GENERAL..............................................................................................398 HOW TO MOVE A DISABLED LIFT TRUCK....................................................................398 How To Tow The Lift Truck............................................................................398 HOW TO PUT A LIFT TRUCK ON BLOCKS....................................................................399 How To Raise Drive Tire..............................................................................399 How To Raise Load Wheels.............................................................................399 MAINTENANCE SCHEDULE.....................................................................................400 MAINTENANCE PROCEDURES- EVERY 8 HOURS OR DAILY...........................................................402 HOW TO MAKE CHECKS WITH KEY SWITCH OFF...............................................................402 Hydraulic System.................................................................................402 Battery..........................................................................................402 Mast, Platform, Forks And Lift Chains............................................................403 Tether Line And Belt.............................................................................404 Pallet Clamp.....................................................................................404 Tire, Wheels and Caster..........................................................................404 HOW TO MAKE CHECKS WITH THE KEY SWITCH ON............................................................405 Gauges, Lights, Horn And Fuses...................................................................405 Switches And Direction/Speed Control.............................................................406 Lift System Operation............................................................................406 Brake............................................................................................406 Steering System..................................................................................406 EVERY 350 HOURS OR TWO MONTHS............................................................................407 HYDRAULIC TANK BREATHER..............................................................................407 ELECTRICAL INSPECTION................................................................................407 Contactors.......................................................................................407 Motor Brushes....................................................................................407 SAFETY LABELS........................................................................................408 MAST.................................................................................................408 CHECK FOR LEAKS IN THE LIFT SYSTEM...................................................................409 Check The Lift Cylinder For Leaks................................................................409 LIFT CHAINS..........................................................................................410 FORKS................................................................................................410 EVERY 2000 HOURS OR YEARLY...............................................................................411 MASTER DRIVE UNIT....................................................................................411 STEERING CHAIN.......................................................................................411 WHEELS AND BEARINGS..................................................................................411 HOW TO CHANGE THE HYDRAULIC OIL AND FILTER...........................................................411 BRAKE................................................................................................412 ELECTRICAL CABLE SHEAVES.............................................................................412 PALLET CLAMP.........................................................................................412 LIMIT SWITCH ROLLERS AND OTHER LUBRICATION...........................................................412 GENERAL PROCEDURES.......................................................................................413 HOW TO CHARGE THE BATTERY............................................................................413 HOW TO CHANGE THE BATTERY............................................................................414 General..........................................................................................414 Remove the Battery...............................................................................414 Install the Battery..............................................................................415 HOW TO CHANGE WHEELS AND TIRES.......................................................................415 How To Change Drive And Steer Tire...............................................................415 How To Replace Load Wheels.......................................................................416 BATTERY SPECIFICATIONS...................................................................................416 mast drive unit..............................................................................................417 INTRODUCTION.............................................................................................418 GENERAL..............................................................................................418 DESCRIPTION..........................................................................................418 REPAIR...................................................................................................420 REMOVAL..............................................................................................420 Mount Type A.....................................................................................420 Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)....................420 Mount Type B (R30DH Only)........................................................................421 DISASSEMBLY..........................................................................................421 ASSEMBLY.............................................................................................423 General..........................................................................................423 Installing The Spiral Bevel Pinion...............................................................425 Installing Thr Spiral Bevel Gear.................................................................426 INSTALLATION.........................................................................................428 Mount Type A.....................................................................................428 Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)....................428 Mount Type B (R30DH Only)........................................................................429 CHECKS AND ADJUSTMENTS...................................................................................430 ADJUST THE BACKLASH AND TOOTH CONTACT................................................................430 ADJUST BEARING CONTACT...............................................................................431 TROUBLESHOOTING..........................................................................................432 metric and inch (sae) fasteners..............................................................................434 General..................................................................................................436 Nomenclature, Threads................................................................................436 Strength Identification..............................................................................437 Fastener Torque Tables...............................................................................441 Conversion Table.....................................................................................443 SCHEMATIC AND DIAGRAM........................................................................................445 FIGURE 1. SCHEMATIC DIAGRAM, EV–100 MOTOR CONTROLLER (WITHOUT WIRE GUIDANCE).............................446 FIGURE 2. WIRING DIAGRAM, EV–100 MOTOR CONTROLLER (WITHOUT WIRE GUIDANCE) (1 of 2).......................448 FIGURE 3. WIRING DIAGRAM, EV–100 MOTOR CONTROLLER (WITHOUT WIRE GUIDANCE) (2 of 2).......................449 FIGURE 4. WIRING DIAGRAM, EV–100 MOTOR CONTROLLER (WITH WIRE GUIDANCE) (1 of 2)..........................450 FIGURE 5. WIRING DIAGRAM, EV–100 MOTOR CONTROLLER (WITH WIRE GUIDANCE) (2 of 2)..........................452 FIGURE 6. SCHEMATIC DIAGRAM, EV–100 MOTOR CONTROLLER (WITH WIRE GUIDANCE)................................454 FIGURE 7. SCHEMATIC DIAGRAM, EV–100LX MOTOR CONTROLLER (WITHOUT WIRE GUIDANCE)...........................456 FIGURE 8. WIRING DIAGRAM, EV–100LX MOTOR CONTROLLER (WITHOUT WIRE GUIDANCE) (1 of 2).....................458 FIGURE 9. WIRING DIAGRAM, EV–100LX MOTOR CONTROLLER (WITHOUT WIRE GUIDANCE) (2 of 2).....................459 FIGURE 10. WIRING DIAGRAM, EV–100LX MOTOR CONTROLLER (WITH WIRE GUIDANCE) (1 of 2).......................460 FIGURE 11. WIRING DIAGRAM, EV–100LX MOTOR CONTROLLER (WITH WIRE GUIDANCE) (2 of 2).......................462 FIGURE 12. SCHEMATIC DIAGRAM, EV–100LX MOTOR CONTROLLER (WITH WIRE GUIDANCE).............................464 FIGURE 13. CABLING AND DETAIL DIAGRAM....................................................................466 FIGURE 14. OPTIONS WIRING AND DETAIL DIAGRAM.............................................................467 FIGURE 15. WIRE GUIDANCE CABLING AND DETAIL DIAGRAM......................................................468 FIGURE 16. HYDRAULIC SCHEMATIC...........................................................................469 tilt cylinders...............................................................................................470 General..................................................................................................472 Description..............................................................................................472 Tilt Cylinder............................................................................................472 Remove...............................................................................................472 Disassemble..........................................................................................472 Clean................................................................................................472 Assemble.............................................................................................472 Tilt Cylinders with O-Ring or Single-Lip Seals...................................................472 Tilt Cylinders for XM and XMS Models.............................................................474 Tilt Cylinders for H700-800A and Early Model H700-920B...........................................475 Install..............................................................................................476 Tilt Cylinders Using Chevron Packing.............................................................477 Install......................................................................................478 Tilt Cylinder Leak Check.................................................................................480 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment......................................................481 Torque Specifications....................................................................................481 Piston Rod Nut.......................................................................................481 Retainer.............................................................................................483 Troubleshooting..........................................................................................484 two-stage and three-stage uprights...........................................................................487 INTRODUCTION.............................................................................................487 General..............................................................................................487 REPAIRS..................................................................................................487 Forks................................................................................................487 Replacement (N40-50ER)...........................................................................487 Replacement (R30E/EA/EA-FS)......................................................................487 Carriage Or Operator Platform........................................................................489 Removal..........................................................................................489 Installation.....................................................................................490 TWO-STAGE UPRIGHT........................................................................................491 Removal..............................................................................................491 Disassembly..........................................................................................493 Cleaning And Inspection..............................................................................494 Lift Cylinders.......................................................................................495 Assembly.............................................................................................496 Installation.........................................................................................496 THREE-STAGE UPRIGHT......................................................................................497 Removal..............................................................................................497 Disassembly..........................................................................................497 Cleaning And Inspection..............................................................................499 Lift Cylinders.......................................................................................499 Assembly.............................................................................................499 Installation.........................................................................................501 GENERAL PROCEDURES.......................................................................................502 Replacing Load Wheels................................................................................502 CHECKS AND ADJUSTMENTS...................................................................................502 Checking For Leaks In The Lift System................................................................502 Lift Chain Adjustments...............................................................................503 Upright Adjustments..................................................................................505 Carriage Or Operator Platform Adjustment.............................................................505 TROUBLESHOOTING..........................................................................................507 upright (2)..................................................................................................508 INTRODUCTION.............................................................................................511 GENERAL..............................................................................................511 REPAIRS..................................................................................................511 FORKS................................................................................................511 Replacement (30E/EA/EA- FS) (See FIGURE 2.)..........................................................511 OPERATOR PLATFORM....................................................................................512 Removal..............................................................................................512 Installation.........................................................................................515 TWO-STAGE UPRIGHT........................................................................................515 REMOVAL..............................................................................................515 DISASSEMBLY (See FIGURE 3., and FIGURE 4.)...........................................................517 CLEANING AND INSPECTION..............................................................................518 LIFT CYLINDERS.......................................................................................518 ASSEMBLY.............................................................................................519 INSTALLATION.........................................................................................520 THREE-STAGE UPRIGHT......................................................................................520 REMOVAL..............................................................................................520 DISASSEMBLY (See FIGURE 4., and FIGURE 6.)...........................................................520 CLEANING AND INSPECTION..............................................................................522 LIFT CYLINDERS.......................................................................................522 ASSEMBLY (See FIGURE 4., and FIGURE 6.)..............................................................522 INSTALLATION.........................................................................................524 GENERAL PROCEDURESS......................................................................................525 REPLACE THE LOAD WHEELS..............................................................................525 CHECKS AND ADJUSYMENTS...................................................................................525 CHECK FOR LEAKS IN THE LIFT SYSTEM...................................................................525 LIFT CHAIN ADJUSTMENT................................................................................525 UPRIGHT ADJUSTMENTS..................................................................................526 OPERATOR PLATFORM ADJUSTMENT.........................................................................527 TROUBLESHOOTING..........................................................................................528 VISTA UPRIGHT REPAIR.....................................................................................528 upright......................................................................................................529 INTRODUCTION.............................................................................................529 General..............................................................................................529 Upright Weldments....................................................................................529 Carriages (N40-50EA Only)............................................................................531 Operator Platform (R30E/EA/EA-FS Only)...............................................................531 VISTA TWO-STAGE UPRIGHTS.................................................................................531 Description..........................................................................................531 Operation............................................................................................534 VISTA THREE-STAGE UPRIGHTS...............................................................................535 Description..........................................................................................535 Operation............................................................................................537 wire guidance (2)............................................................................................539 INTRODUCTION.............................................................................................539 GENERAL..............................................................................................539 REPAIR...................................................................................................539 STEERING MECHANISM...................................................................................539 Removal And Disassembly..........................................................................539 Assembly And Installation........................................................................540 REPLACE GUIDANCE SWITCH, INDICATOR AND ALARM.........................................................541 REPLACE MDU POTENTIOMETER............................................................................541 REPLACE THE ECM......................................................................................542 Replace The Complete Module......................................................................542 Replace The Logic Board Set......................................................................542 Replace ECM Power Transistors....................................................................543 REPLACE THE STEERING CONTACTOR.......................................................................545 REPLACE THE GEARMOTOR ASSEMBLY AND STEERING CHAIN....................................................545 REPLACE THE SENSORS..................................................................................547 wire guidance................................................................................................551 INTRODUCTION.............................................................................................551 General..............................................................................................551 Operation............................................................................................552 How To Operate The Wire Guidance System..........................................................552 CHECKS AND ADJUSTMENTS...................................................................................554 General..............................................................................................554 Checks...............................................................................................555 Checking For Short-Ciruits To The Frame..........................................................556 General......................................................................................556 Checks.......................................................................................556 Automatic Checks.............................................................................556 Manual Checks....................................................................................558 Check 01 - Operator Controls.................................................................558 Check 02 - Steering Input Voltage............................................................558 Check 03 - Mdu Potentiometer Coarse Amplifier................................................559 Check 04 - MDU Centering....................................................................559 Check 05 - Direction Inputs..................................................................559 Checks 06 Through 09 - Sensor Levels.........................................................559 Check 10 - Steered End Sensor Balance........................................................560 Check 11 - Load End Sensor Balance...........................................................560 Check 12 - Load End First Ratio..............................................................560 Check 13 - Medium Travel Speed...............................................................560 Check 14 - Slow Travel Speed.................................................................560 Check 15 - Truck Configuration...............................................................560 Checking Operation Of Shut-off Circuit.......................................................560 Checking Steering At Upright Heights.........................................................561 Checking The Ecm Power Transistors...........................................................561 Checking The Steering Contactor..............................................................561 Adjustments..........................................................................................562 General..........................................................................................562 Adjusting The Return-To-Center Steer And Range Potentiometers....................................563 Adjusting The Balance Of The Steering Input Signal...............................................564 Setting The MDU For Straight Travel..............................................................564 Adjusting The Travel Speeds......................................................................565 Medium Speed.................................................................................565 Slow Speed...................................................................................566 Setting Truck Configuration......................................................................567 Adjusting Sensors To Lift Truck Centerline.......................................................567 Adjusting The Steering Chain.....................................................................568
HYSTER D118 (R30E,EA R30EF R35E) SERVICE MANUAL – PDF DOWNLOAD:
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