Hyster E118 Service Manual – PDF DOWNLOAD

Description

Hyster E118 Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster E118 Service Manual – PDF DOWNLOAD

SAFETY P RECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemЫies, make sure that all slings, chains or саЫеs
are correctly fastened and that the load being lifted is balanced. Make sure
that the crane, саЫеs and chains have the capacity to support the weight of
the load.
• Do not lift heavy parts Ьу hand. U se а lifting mechanism.
• Wear safety glasses.
• DISCONNECT ТНЕ BAT TERY CONNECTOR before doing any
maintenance or repair оп electric lift trucks. Disconnect the battery ground
саЫе оп intemal combustion lift trucks.
• Always use correct Ыocks to prevent the unit from rolling or falling. See
“How То Put The Lift Truck Оп Вlocks” in the OPERATING MANUAL or
the PERIODIC MAINTENANCE section.
• Кеер the unit and working area clean and in order.
• Use the correct tools for the job.
• Кеер 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 that all nuts, bolts, snap rings and other fastening devices are
removed before using force to remove parts.
• Always fasten а DO NOT ОРЕRАТЕ sign to the controls of the unit when
making repairs or if the unit needs repairs.
• Make sure you follow the DANGER, WARNING and CAUTION notes in
the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammaЫe fuels.
Make sure that you follow the necessary safety precautions when handling
these fuels and when working оп these fuel systems.
• Batteries generate flammaЫe gas when they are being charged. Кеер ftre and
sparks away from the area. Make sure the area has ventilation.

TABLE OF CONTENTS:

Hyster E118 Service Manual – PDF DOWNLOAD

1600418.........................................................................................  1
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	............................................................................................ 19
	............................................................................................ 20
1600691......................................................................................... 21
	toc......................................................................................... 21
		Power Steering.......................................................................... 21
		Safety Precautions Maintenance and Repair............................................... 22
		General................................................................................. 25
			EPS III............................................................................. 25
			APS................................................................................. 25
		Description............................................................................. 25
			EPS III............................................................................. 25
			APS System.......................................................................... 26
		Checks and Adjustments.................................................................. 26
			General............................................................................. 26
			Checks, EPS III..................................................................... 26
				Dipswitches, EPS III............................................................ 26
				LED Indicators, EPS III......................................................... 27
				Check Steering System for Correct Operation, EPS III............................ 27
				Check Slow Travel Speed, EPS III................................................ 27
				Check High Lift Traction Shutoff, EPS III....................................... 28
			Checks, APS......................................................................... 28
				Dipswitches, APS................................................................ 28
				LED Indicators, APS............................................................. 28
			Adjustments......................................................................... 28
				General......................................................................... 28
				Steer Motor With Steering Chain Replacement, EPS III............................ 29
				Steer Motor With Steering Gear Replacement, APS................................. 29
				Return-to-Center Steering System................................................ 29
					Command Potentiometer Adjustment, EPS III................................... 29
					Feedback Potentiometer Adjustment (Earlier Models Only)..................... 31
				Tach Generator Steering System, EPS III......................................... 34
					Tach Generator Adjustment, EPS III.......................................... 34
					Sensitivity Adjustment, EPS III............................................. 34
					Feedback Potentiometer Adjustment, EPS III.................................. 34
				Slow Travel Adjustment, EPS III................................................. 35
				Return-to-Center and Multiturn System, APS...................................... 36
					Encoder Replacement, APS.................................................... 36
				Steering Chain Adjustment, EPS III.............................................. 36
		Repairs................................................................................. 37
			RTC Steering System, EPS III........................................................ 37
				Command Potentiometer Replacement, EPS III...................................... 37
			TGS System, EPS III................................................................. 38
				Tach Generator Replacement, EPS III............................................. 38
			Feedback Potentiometer Replacement, EPS III......................................... 38
			ECM Replacement, EPS III............................................................ 38
			Steer Motor Assembly and Steering Chain Replacement, EPS III........................ 38
		Typical Operating Voltages, EPS III..................................................... 39
		Steering Proximity Switch and Centering Proximity Switch, APS........................... 40
		Troubleshooting......................................................................... 41
			EPS III............................................................................. 41
			APS................................................................................. 42
	tables...................................................................................... 21
		Table 1. LED Indicators................................................................. 27
		Table 2. Sensitivity Adjustment......................................................... 34
		Table 3. Typical Operating Voltages..................................................... 39
2200420......................................................................................... 45
	CHECKS AND ADJUSTMENTS...................................................................... 45
		GENERAL................................................................................. 45
		CONTROL AND POWER FUSES................................................................. 45
		EV-100 MOTOR CONTROLLER................................................................. 46
			EV-100 Traction Control Card........................................................ 46
				Adjust Creep Speed, "CREEP"..................................................... 46
				Adjust Controlled Acceleration, "C/A"........................................... 46
				Adjust Current Limit, "C/L"..................................................... 46
		ACCELERATOR POTENTIOMETER............................................................... 47
		FORWARD AND REVERSE SWITCHES............................................................ 49
		LIMIT SWITCH LS-1 AND LS-3 (Traction Cutout And Traction Override)...................... 49
		LOOSE CHAIN SWITCH...................................................................... 49
		LIMIT SWITCH LS-2 (Lowering Speed, Travel Speed)........................................ 50
	REPAIR...................................................................................... 50
		GENERAL................................................................................. 50
		REPLACE THE ELECTRICAL PARTS OF THE STEERING, HYDRAULIC OR OPTIONAL GUIDANCE SYSTEMS.... 51
		REPLACE THE ACCELERATOR POTENTIOMETER................................................... 51
		REPLACE THE KEY AND OTHER CONSOLE SWITCHES AND INDICATOR LIGHTS......................... 51
		REPLACE SWITCHES IN THE DIRECTION/SPEED CONTROL......................................... 52
			Replace The Foot Switch............................................................. 53
			Replace Loose Chain Switch.......................................................... 53
		REPLACE THE LIMIT SWITCHES.............................................................. 54
			Limit Switch LS-1 (Upright)......................................................... 54
			Limit Switch LS-2 (Lowering Speed).................................................. 55
8000410......................................................................................... 56
	INTRODUCTION................................................................................ 56
		GENERAL................................................................................. 56
		HOW TO MOVE A DISABLED LIFT TRUCK....................................................... 56
		How To Tow The Lift Truck............................................................... 56
		HOW TO PUT A LIFT TRUCK ON BLOCKS....................................................... 57
		How To Raise Drive Tire................................................................. 57
		How To Raise Load Wheels................................................................ 57
	MAINTENANCE SCHEDULE........................................................................ 58
	MAINTENANCE PROCEDURES- EVERY 8 HOURS OR DAILY.............................................. 60
		HOW TO MAKE CHECKS WITH KEY SWITCH OFF.................................................. 60
			Hydraulic System.................................................................... 60
			Battery............................................................................. 60
			Mast, Platform, Forks And Lift Chains............................................... 61
			Tether Line And Belt................................................................ 62
			Pallet Clamp........................................................................ 62
			Tire, Wheels and Caster............................................................. 62
		HOW TO MAKE CHECKS WITH THE KEY SWITCH ON............................................... 63
			Gauges, Lights, Horn And Fuses...................................................... 63
			Switches And Direction/Speed Control................................................ 64
			Lift System Operation............................................................... 64
			Brake............................................................................... 64
			Steering System..................................................................... 64
	EVERY 350 HOURS OR TWO MONTHS............................................................... 65
		HYDRAULIC TANK BREATHER................................................................. 65
		ELECTRICAL INSPECTION................................................................... 65
			Contactors.......................................................................... 65
			Motor Brushes....................................................................... 65
		SAFETY LABELS........................................................................... 66
		MAST.................................................................................... 66
		CHECK FOR LEAKS IN THE LIFT SYSTEM...................................................... 67
			Check The Lift Cylinder For Leaks................................................... 67
		LIFT CHAINS............................................................................. 68
		FORKS................................................................................... 68
	EVERY 2000 HOURS OR YEARLY.................................................................. 69
		MASTER DRIVE UNIT....................................................................... 69
		STEERING CHAIN.......................................................................... 69
		WHEELS AND BEARINGS..................................................................... 69
		HOW TO CHANGE THE HYDRAULIC OIL AND FILTER.............................................. 69
		BRAKE................................................................................... 70
		ELECTRICAL CABLE SHEAVES................................................................ 70
		PALLET CLAMP............................................................................ 70
		LIMIT SWITCH ROLLERS AND OTHER LUBRICATION.............................................. 70
	GENERAL PROCEDURES.......................................................................... 71
		HOW TO CHARGE THE BATTERY............................................................... 71
		HOW TO CHANGE THE BATTERY............................................................... 72
			General............................................................................. 72
			Remove the Battery.................................................................. 72
			Install the Battery................................................................. 73
		HOW TO CHANGE WHEELS AND TIRES.......................................................... 73
			How To Change Drive And Steer Tire.................................................. 73
			How To Replace Load Wheels.......................................................... 74
	BATTERY SPECIFICATIONS...................................................................... 74
8000423......................................................................................... 75
	BATTERY SPECIFICATIONS...................................................................... 75
	TRANSISTOR CONTROLLER ADJUSTMENT POINTS..................................................... 75
	EV–100 TRACTION CARD SETTINGS............................................................... 75
	MASTER DRIVE UNIT........................................................................... 75
	SYSTEM II ELECTRONIC CONTROL MODULE (ELECTRIC POWER STEERING)............................... 76
	TERMINAL AND PIN ARRANGEMENTS FOR THE EV–100 CONTROL CARD................................... 77
	TERMINAL AND PIN ARRANGEMENTS FOR THE CURTIS 1204X – 4406................................... 78
	SYSTEM II ELECTRONIC CONTROL MODULE (WIRE GUIDANCE)......................................... 79
	TRANSISTOR RESISTANCE....................................................................... 79
	SYSTEM II WIRE GUIDANCE SPECIFICATIONS...................................................... 80
	HYDRAULIC SYSTEM............................................................................ 81
	TORQUE SPECIFICATIONS....................................................................... 81
8000474......................................................................................... 83
	FIGURE 1. HYDRAULIC SCHEMATIC............................................................... 83
	FIGURE 2. SCHEMATIC DIAGRAM WITHOUT WIRE GUIDANCE........................................... 85
	FIGURE 3. WIRING DIAGRAM-MOTOR COMPARTMENT-WITHOUT WIRE GUIDANCE............................ 87
	FIGURE 4. WIRING DIAGRAM-OPERATOR'S PLATFORM-WITHOUT WIRE GUIDANCE.......................... 89
	FIGURE 5. SCHEMATIC DIAGRAM WITH WIRE GUIDANCE.............................................. 91
	FIGURE 6. WIRING DIAGRAM-MOTOR COMPARTMENT-WITH WIRE GUIDANCE............................... 93
	FIGURE 7. WIRING DIAGRAM-OPERATOR'S PLATFORM-WITH WIRE GUIDANCE............................. 95
	FIGURE 8. WIRING DIAGRAM-OPTIONAL EQUIPMENT................................................. 97
	FIGURE 9. CABLING AND DETAIL DIAGRAM........................................................ 99
	FIGURE 10. CABLING AND DETAIL DIAGRAM.......................................................100
	FIGURE 11. WIRE GUIDANCE AND DETAIL DIAGRAM.................................................101

HYSTER E118 SERVICE MANUAL – PDF DOWNLOAD:

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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