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Hyster D174 Service Manual – PDF DOWNLOAD
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Description
Hyster D174 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster D174 Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR:
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster D174 Service Manual – PDF DOWNLOAD
897340-2200SRM0411-(06-2004)-US-EN.................................................. 1 toc............................................................................. 1 Curtis Transistor Motor Controller.......................................... 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Principles of Operation..................................................... 6 General................................................................. 6 Transistor Motor Controller............................................. 7 Basic Controller Operation.......................................... 9 Field Effect Transistor (FET)....................................... 9 Motor Circuit That Operates With Pulses............................. 9 Induction Current From Motor........................................ 11 Plugging............................................................ 12 Control Circuit..................................................... 13 Static-Return-To-Off (SRO) Function................................. 13 Thermal Protection Function......................................... 14 Low Voltage Protection Function..................................... 14 Current Limit Protection Function................................... 14 Power Circuit....................................................... 14 Sequence of Operation....................................................... 16 Key Switch.............................................................. 16 Brake Switch............................................................ 16 Control Circuit......................................................... 16 FWD/REV Switch Closed................................................... 16 Forward Contactor Energized............................................. 16 Gate Pulse to FETs...................................................... 16 FETs ON for Time of Gate Pulse.......................................... 16 Gate Pulse Removed...................................................... 16 Induction Current Flows Through Motor and Flyback Diode................. 24 Plugging................................................................ 24 Checks...................................................................... 26 Checking Contactor Coil................................................. 26 Checking Transistor Controller.......................................... 26 Checks With Controller Installed.................................... 27 Bench Checks........................................................ 29 Accelerator Potentiometer Checks and Adjustments.................... 30 Adjustments................................................................. 31 Plugging Adjustment..................................................... 32 Acceleration Adjustment................................................. 32 Current Limit Adjustment................................................ 32 Repairs..................................................................... 32 Contactors.............................................................. 32 Replace............................................................. 34 Curtis Contactor Parts, Replace......................................... 34 GE Contactor Parts, Replace............................................. 34 Controller, Replace..................................................... 36 Accelerator Potentiometer and Control Switches, Replace and Adju........ 36 Troubleshooting............................................................. 36 General................................................................. 36 General Procedures...................................................... 37 Fault Procedures............................................................ 37 tables.......................................................................... 1 Table 1. Inductance......................................................... 11 Table 2. Fault Codes and Display Messages for R30XMS2 Only.................. 43 910114-2260SRM0138-(06-2002)-US-EN.................................................. 51 toc............................................................................. 51 Battery Indicators.......................................................... 51 Safety Precautions Maintenance and Repair................................... 52 General..................................................................... 55 Indicators With Meter Movements......................................... 55 Battery Indicators With LCD or LED Displays............................. 58 Liquid Crystal Displays............................................. 58 Display Panels Description (ZX or Earlier Motor Controllers).... 58 SEM Display Panels Description...................................... 60 Light Emitting Diode Displays....................................... 61 Description LX Series............................................... 61 ZX Series Display Panels Description................................ 63 SEVCON POWERGAUGE—42 Battery Display Panel Description.............. 64 Battery Indicators Without Lift Interrupt Adjustment (Early Mode............ 64 Battery Indicators With Lift Interrupt Adjustment (Early Models)............ 65 Reset Potentiometer..................................................... 65 Specific Gravity Alarm.................................................. 65 Battery Indicators Without Lift Interrupt Check (Later Models).............. 66 Battery Indicators With Lift Interrupt Adjustment (Later Models)............ 66 Reset Potentiometer..................................................... 66 Discharge Potentiometer................................................. 66 LED Display With Lift Interrupt............................................. 67 Curtis 933-1 Meter Check and Adjustment..................................... 67 Check................................................................... 67 Reset Check......................................................... 68 Discharge Check..................................................... 68 Lockout Check....................................................... 69 LEDs Do Not Illuminate.............................................. 69 Hourmeter Check..................................................... 69 Hourglass Icon...................................................... 69 Adjust.................................................................. 69 SEVCON POWERGAUGE—42 Adjustment............................................. 70 Curtis Dash Display Assembly................................................ 70 Description/Features.................................................... 70 Operation............................................................... 71 Testing................................................................. 71 Inoperative Dash Display Assembly................................... 71 Inoperative Drive Mode Selection.................................... 72 Troubleshooting With a Programmer Handset........................... 72 Troubleshooting Without a Programmer Handset........................ 73 No Warnings or Faults Displayed..................................... 73 MIB/Dash Display Communication...................................... 74 Lift Interrupt...................................................... 74 Lost MIB Signal Displayed........................................... 75 Lift Pump Hourmeter Input........................................... 75 Forward/Reverse Hourmeter Inputs.................................... 75 Remove.................................................................. 76 Install................................................................. 76 Adjust (Setup, Early Models)............................................ 76 Adjust (Setup, Later Model)............................................. 77 Battery Indicators Replacement.............................................. 78 Battery Indicator Controller Replacement.................................... 78 Display Panel Components Replacement........................................ 79 SEM Display Panel Replacement............................................... 79 Remove and Replace...................................................... 79 tables.......................................................................... 51 Table 1. Battery Indicator (Later Models)................................... 66 Table 2. SEVCON Discharge Curve Selector Positions.......................... 70 Table 3. Dash Display Drive Mode Inputs..................................... 72 Table 4. Dash Display Drive Mode Test Voltages.............................. 73 Table 5. Dash Display Status/Warning/Fault Test Voltages.................... 74 Table 6. Testing Dash Display Status/Warning/Fault Inputs................... 74 Table 7. Battery Indicator Reset Adjustment................................. 77 1453810-1600SRM0691-(02-2002)-US-EN................................................. 85 toc............................................................................. 85 Power Steering.............................................................. 85 Safety Precautions Maintenance and Repair................................... 86 General..................................................................... 89 EPS III................................................................. 89 APS..................................................................... 89 Description................................................................. 89 EPS III................................................................. 89 APS System.............................................................. 90 Checks and Adjustments...................................................... 90 General................................................................. 90 Checks, EPS III......................................................... 90 Dipswitches, EPS III................................................ 90 LED Indicators, EPS III............................................. 91 Check Steering System for Correct Operation, EPS III................ 91 Check Slow Travel Speed, EPS III.................................... 91 Check High Lift Traction Shutoff, EPS III........................... 92 Checks, APS............................................................. 92 Dipswitches, APS.................................................... 92 LED Indicators, APS................................................. 92 Adjustments............................................................. 92 General............................................................. 92 Steer Motor With Steering Chain Replacement, EPS III................ 93 Steer Motor With Steering Gear Replacement, APS..................... 93 Return-to-Center Steering System.................................... 93 Command Potentiometer Adjustment, EPS III....................... 93 Feedback Potentiometer Adjustment (Earlier Models Only)......... 95 Tach Generator Steering System, EPS III............................. 98 Tach Generator Adjustment, EPS III.............................. 98 Sensitivity Adjustment, EPS III................................. 98 Feedback Potentiometer Adjustment, EPS III...................... 98 Slow Travel Adjustment, EPS III..................................... 99 Return-to-Center and Multiturn System, APS..........................100 Encoder Replacement, APS........................................100 Steering Chain Adjustment, EPS III..................................100 Repairs.....................................................................101 RTC Steering System, EPS III............................................101 Command Potentiometer Replacement, EPS III..........................101 TGS System, EPS III.....................................................102 Tach Generator Replacement, EPS III.................................102 Feedback Potentiometer Replacement, EPS III.............................102 ECM Replacement, EPS III................................................102 Steer Motor Assembly and Steering Chain Replacement, EPS III............102 Typical Operating Voltages, EPS III.........................................103 Steering Proximity Switch and Centering Proximity Switch, APS...............104 Troubleshooting.............................................................105 EPS III.................................................................105 APS.....................................................................106 tables.......................................................................... 85 Table 1. LED Indicators..................................................... 91 Table 2. Sensitivity Adjustment............................................. 98 Table 3. Typical Operating Voltages.........................................103 1490102-8000SRM0923-(11-2004)-US-EN.................................................109 toc.............................................................................109 Diagrams....................................................................109 Safety Precautions Maintenance and Repair...................................110 1493912-2200SRM0933-(08-2005)-US-EN.................................................125 toc.............................................................................125 Electrical System...........................................................125 Safety Precautions Maintenance and Repair...................................126 Major Electrical System Features............................................131 Integrated System.......................................................131 CAN Bus Advantages......................................................131 CAN Bus Communications..................................................131 Electric Steering...................................................131 Traction............................................................131 Master Control Unit.................................................131 Input Devices...................................................131 Output Devices..................................................132 Encoder Integrity.......................................................132 Test Encoders...........................................................132 Proximity Switches......................................................132 Start Relay.............................................................132 Battery Discharge Indicator (BDI).......................................132 Multifunction Display...................................................133 Setup.......................................................................133 Setup Instructions......................................................133 General Diagnostics.....................................................138 Power-On Self-Test..........................................................139 SEM Traction Motor Controller...............................................139 Controller Removal......................................................140 Install.................................................................140 Low-Voltage Protection Function.........................................140 Checking Contactor Coils................................................141 Checking Transistor Controller..............................................141 Component Repair and Testing............................................141 Troubleshooting.........................................................142 Fault Codes and Display Messages........................................143 Contactor and Electrical Panel Checks.......................................156 Fuses...................................................................156 Contactors..............................................................156 General.............................................................156 Test................................................................157 Tips................................................................158 Disassemble and Assemble............................................158 Traction Throttle Sensor Removal and Installation...........................159 Instrument Panel Removal and Installation...................................161 Key Switch Removal and Installation.........................................161 Remove..................................................................161 Install.................................................................161 Steering Indicator Gauge....................................................161 Test....................................................................161 Remove and Install......................................................161 Spy Glass Removal and Installation..........................................162 Foot Switch Removal and Installation........................................162 Slack Chain Switch Removal and Installation.................................163 Limit Switch Removal and Installation.......................................164 Drive and Hydraulic Pump Motors.............................................164 Routine Preventive Maintenance..........................................164 Preventive Maintenance Checks.......................................165 Cleanliness.............................................................165 Connections.............................................................165 Discoloration and Burn Marks............................................165 Brushes.................................................................165 Short in Armature.......................................................165 Commutator..............................................................165 Bearings................................................................166 Causes of Motor Failure.....................................................166 Overload................................................................166 Shock Loading...........................................................166 Short in Field Coils....................................................166 Short Brushes...........................................................166 High or Low Commutator Bar..............................................166 Open Circuit............................................................166 Low Battery Voltage.....................................................166 Eccentricity of Commutator..............................................166 Overspeeding............................................................166 Motor Tests.................................................................167 Excessive Current Draw..................................................167 Measuring Current Draw..................................................167 Excessive Resistance....................................................167 Brush Springs...........................................................167 Drive Motor.................................................................168 Inspect.................................................................168 Preparation of Drive Motor Commutator...................................168 Fitting Motor Brushes (Motor Removed).......................................169 Drive Motor Brush and Brush Holder..........................................169 Drive Motor Brush, Remove and Install (Motor Installed).................169 Drive Motor Brush Holder, Remove and Install (Motor Installed)..........169 Drive Motor Disassembly and Assembly........................................170 Hoist Pump Motors...........................................................172 Maintenance Instructions................................................172 General Information.....................................................173 Brush Replacement.......................................................173 Hoist Motor.............................................................173 Remove and Install..................................................173 Disassemble and Assemble............................................173 Height Encoder Troubleshooting..............................................175 Description.............................................................175 Symptoms................................................................175 24......................................................................175 Height Encoder Diagnostics..............................................175 Symptoms and Recommendations............................................175 Travel Speed Reduction..................................................176 Additional Encoder Check................................................176 Steer Encoder Troubleshooting...............................................176 Description.............................................................176 MDU Proximity Switch Issues.............................................177 Steering System Issues..................................................177 How to Check the Steer Encoder..........................................177 tables..........................................................................125 Table 1. Fault Codes and Display Messages...................................143 Table 2. Coil Resistance....................................................157 1496736-2200SRM0957-(08-2001)-US-EN.................................................181 toc.............................................................................181 Wire Guidance...............................................................181 Safety Precautions Maintenance and Repair...................................182 General.....................................................................185 Setup Instructions..........................................................186 Setup Mode..............................................................186 Setup Procedure.........................................................186 Check Sensor Mounting...............................................186 Align Steering......................................................186 Multiturn Trucks Only...........................................186 Self-Centering Trucks Only......................................186 Calibrate Guidance Control System...................................186 Check Operation of System...........................................187 Troubleshooting.........................................................187 Check Guide Wire....................................................187 Is Guidance Option Enabled?.........................................187 Check Software Configuration........................................187 Check Sensors.......................................................187 Check Control Cable.................................................187 Check Steering System...............................................187 Check Steer Chain Tension...........................................187 Guidance Switch Replacement.................................................188 Sensors Replacement.........................................................188 1534734-2200SRM1055-(03-2003)-US....................................................193 toc.............................................................................193 Wire Guidance...............................................................193 Safety Precautions Maintenance and Repair...................................194 General.....................................................................197 Setup Instructions..........................................................198 Setup Mode..............................................................198 Setup Procedure.........................................................198 Check Sensor Mounting...............................................198 Align Steering......................................................198 Multiturn Trucks Only...........................................198 Self-Centering Trucks Only......................................198 Calibrate Guidance Control System...................................198 Check Operation of System...........................................199 Troubleshooting.........................................................199 Check Guide Wire....................................................199 Is Guidance Option Enabled?.........................................199 Check Software Configuration........................................199 Check Sensors.......................................................199 Check Control Cable.................................................199 Check Steering System...............................................199 Check Steer Chain Tension...........................................199 Guidance Switch Replacement.................................................200 Sensors Replacement.........................................................200 1534735-2200SRM1056-(03-2003)-US....................................................205 toc.............................................................................205 Power Steering..............................................................205 Safety Precautions Maintenance and Repair...................................206 General.....................................................................209 EPS III.................................................................209 APS.....................................................................209 Description.................................................................209 EPS III.................................................................209 APS System..............................................................210 Checks and Adjustments......................................................210 General.................................................................210 Checks, EPS III.........................................................210 Dipswitches, EPS III................................................210 LED Indicators, EPS III.............................................211 Check Steering System for Correct Operation, EPS III................211 Check Slow Travel Speed, EPS III....................................211 Check High Lift Traction Shutoff, EPS III...........................212 Checks, APS.............................................................212 Dipswitches, APS....................................................212 LED Indicators, APS.................................................212 Adjustments.............................................................212 General.............................................................212 Steer Motor With Steering Chain Replacement, EPS III................213 Steer Motor With Steering Gear Replacement, APS.....................213 Return-to-Center Steering System....................................213 Command Potentiometer Adjustment, EPS III.......................213 Feedback Potentiometer Adjustment (Earlier Models Only).........215 Tach Generator Steering System, EPS III.............................218 Tach Generator Adjustment, EPS III..............................218 Sensitivity Adjustment, EPS III.................................218 Feedback Potentiometer Adjustment, EPS III......................218 Slow Travel Adjustment, EPS III.....................................219 Return-to-Center and Multiturn System, APS..........................220 Encoder Replacement, APS........................................220 Steering Chain Adjustment, EPS III..................................220 Repairs.....................................................................221 RTC Steering System, EPS III............................................221 Command Potentiometer Replacement, EPS III..........................221 TGS System, EPS III.....................................................222 Tach Generator Replacement, EPS III.................................222 Feedback Potentiometer Replacement, EPS III.............................222 ECM Replacement, EPS III................................................222 Steer Motor Assembly and Steering Chain Replacement, EPS III............222 Typical Operating Voltages, EPS III.........................................223 Steering Proximity Switch and Centering Proximity Switch, APS...............224 Troubleshooting.............................................................225 EPS III.................................................................225 APS.....................................................................226 tables..........................................................................205 Table 1. LED Indicators.....................................................211 Table 2. Sensitivity Adjustment.............................................218 Table 3. Typical Operating Voltages.........................................223 1600418.............................................................................229 ................................................................................229 ................................................................................230 ................................................................................231 ................................................................................232 ................................................................................233 ................................................................................234 ................................................................................235 ................................................................................236 ................................................................................237 ................................................................................238 ................................................................................239 ................................................................................240 ................................................................................241 ................................................................................242 ................................................................................243 ................................................................................244 ................................................................................245 ................................................................................246 ................................................................................247 ................................................................................248 1600691.............................................................................249 toc.............................................................................249 Power Steering..............................................................249 Safety Precautions Maintenance and Repair...................................250 General.....................................................................253 EPS III.................................................................253 APS.....................................................................253 Description.................................................................253 EPS III.................................................................253 APS System..............................................................254 Checks and Adjustments......................................................254 General.................................................................254 Checks, EPS III.........................................................254 Dipswitches, EPS III................................................254 LED Indicators, EPS III.............................................255 Check Steering System for Correct Operation, EPS III................255 Check Slow Travel Speed, EPS III....................................255 Check High Lift Traction Shutoff, EPS III...........................256 Checks, APS.............................................................256 Dipswitches, APS....................................................256 LED Indicators, APS.................................................256 Adjustments.............................................................256 General.............................................................256 Steer Motor With Steering Chain Replacement, EPS III................257 Steer Motor With Steering Gear Replacement, APS.....................257 Return-to-Center Steering System....................................257 Command Potentiometer Adjustment, EPS III.......................257 Feedback Potentiometer Adjustment (Earlier Models Only).........259 Tach Generator Steering System, EPS III.............................262 Tach Generator Adjustment, EPS III..............................262 Sensitivity Adjustment, EPS III.................................262 Feedback Potentiometer Adjustment, EPS III......................262 Slow Travel Adjustment, EPS III.....................................263 Return-to-Center and Multiturn System, APS..........................264 Encoder Replacement, APS........................................264 Steering Chain Adjustment, EPS III..................................264 Repairs.....................................................................265 RTC Steering System, EPS III............................................265 Command Potentiometer Replacement, EPS III..........................265 TGS System, EPS III.....................................................266 Tach Generator Replacement, EPS III.................................266 Feedback Potentiometer Replacement, EPS III.............................266 ECM Replacement, EPS III................................................266 Steer Motor Assembly and Steering Chain Replacement, EPS III............266 Typical Operating Voltages, EPS III.........................................267 Steering Proximity Switch and Centering Proximity Switch, APS...............268 Troubleshooting.............................................................269 EPS III.................................................................269 APS.....................................................................270 tables..........................................................................249 Table 1. LED Indicators.....................................................255 Table 2. Sensitivity Adjustment.............................................262 Table 3. Typical Operating Voltages.........................................267 2200421.............................................................................273 INTRODUCTION....................................................................273 General.....................................................................273 Operation...................................................................274 How To Operate The Wire Guidance System.................................274 CHECKS AND ADJUSTMENTS..........................................................276 General.....................................................................276 Checks......................................................................277 Checking For Short-Ciruits To The Frame.................................278 General.............................................................278 Checks..............................................................278 Automatic Checks....................................................278 Manual Checks...........................................................280 Check 01 - Operator Controls........................................280 Check 02 - Steering Input Voltage...................................280 Check 03 - Mdu Potentiometer Coarse Amplifier.......................281 Check 04 - MDU Centering...........................................281 Check 05 - Direction Inputs.........................................281 Checks 06 Through 09 - Sensor Levels................................281 Check 10 - Steered End Sensor Balance...............................282 Check 11 - Load End Sensor Balance..................................282 Check 12 - Load End First Ratio.....................................282 Check 13 - Medium Travel Speed......................................282 Check 14 - Slow Travel Speed........................................282 Check 15 - Truck Configuration......................................282 Checking Operation Of Shut-off Circuit..............................282 Checking Steering At Upright Heights................................283 Checking The Ecm Power Transistors..................................283 Checking The Steering Contactor.....................................283 Adjustments.................................................................284 General.................................................................284 Adjusting The Return-To-Center Steer And Range Potentiometers...........285 Adjusting The Balance Of The Steering Input Signal......................286 Setting The MDU For Straight Travel.....................................286 Adjusting The Travel Speeds.............................................287 Medium Speed........................................................287 Slow Speed..........................................................288 Setting Truck Configuration.............................................289 Adjusting Sensors To Lift Truck Centerline..............................289 Adjusting The Steering Chain............................................290
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