Hyster C176 (R40EH) Service Manual - Image 2

Hyster C176 (R40EH) Service Manual - Image 3

Hyster C176 (R40EH) Service Manual - Image 4

Hyster C176 (R40EH) Service Manual - Image 5

Hyster C176 (R40EH) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 489
Size: 17.0MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- C176 (R40EH)

1. INTRODUCTION
2. GENERAL
3. LEAD-ACID BATTERIES
4. SPECIFIC GRAVITY
5. THE CHEMICAL REACTION IN A CELL
6. ELECTRICAL TERMS
7. HOW TO SELECT THE BATTERY
8. VOLTAGE OF A BATTERY
9. THE BATTERY AS A COUNTERWEIGHT
10. BATTERY RATINGS
11. Kilowatt-Hours
12. BATTERY MAINTENANCE
13. SAFETY PROCEDURES
14. MAINTENACE RECORDS
15. THE NEW BATTERY
16. HOW TO CLEAN THE BATTERY
17. HOW TO ADD WATER
18. THE HYDROMETER
19. BATTERY TEMPERATURE
20. CHARGING THE BATTERY
21. Types Of Battery Charges
22. Methods Of Charging
23. Troubleshooting The Charger
24. How To Know When The Battery Is Fully Charged
25. WHERE TO CHARGE THE BATTERIES
26. Equipment Needed
27. BATTERY CONNECTORS
28. BATTERY CARE
29. INTRODUCTION
30. General
31. Description
32. Removal and Disassembly, Load Wheels, Guide Rollers
33. Assembly and Installation, Load Wheels, Guide Rollers
34. PAINTING INSTRUCTIONS
35. DECAL INSTALLATION
36. INTRODUCTION
37. GENERAL
38. DESCRIPTION
39. OPERATION
40. REPAIRS
41. STEERING WHEEL AND COLUMN ASSEMBLY
42. TYPE A STEERING COLUMN ASSEMBLY
43. Removal And Disassembly
44. Assembly And Installation
45. TYPE A STEERING COLUMN
46. TYPE A STEERING COLUMN
47. TYPE B STEERING COLUMN
48. Removal And Disassembly
49. Assembly And Installation
50. TYPE B STEERING COLUMN
51. Disassembly of Steering Control Unit
52. Cleaning of Steering Control Unit
53. Assembly of Steering Control Unit
54. CHECKS AND ADJUSTMENTS
55. REMOVE AIR FROM THE SYSTEM
56. TROUBLESHOOTING
57. INTRODUCTION
58. DESCRIPTION
59. OPERATION
60. Flow Control Valve
61. Relief Valve
62. REPAIRS
63. REMOVAL
64. DISASSEMBLY
65. CLEANING
66. INSPECTION
67. ASSEMBLY
68. INSTALLATION
69. CHECKS AND ADUSTMENTS
70. CHECK THE OUTPUT OF THE PUMP
71. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
72. TROUBLESHOOTING
73. DC Motor Maintenance
74. Safety Precautions Maintenance and Repair
75. General
76. Brush and Commutator Inspection
77. Hydraulic Pump Motor and Traction Motor
78. Steering Pump Motor
79. Normal Commutator Surface
80. Commutator Problems
81. Brush Replacement
82. Stoning the Commutator
83. Motors Repair
84. Disassemble
85. Traction Motor and Hydraulic Pump Motor
86. Steering Pump Motor
87. Assemble
88. Traction Motor and Hydraulic Pump Motor
89. Steering Pump Motor
90. Brush Alignment, Traction and Hydraulic Motors
91. Tests for Damaged Field and Armature
92. Test for an Open Circuit in Armature
93. Test for Short Circuit in One Armature Winding
94. Test for Short Circuit to Armature Shaft
95. Test for Open Circuit in Field Coil
96. Test for Short Circuit in Field Coil
97. Test for Short Circuit between Field and Motor Case
98. Brush Holder Test
99. Troubleshooting
100. Table 1. Normal Commutator Surfaces
101. Table 2. Commutator Problems
102. Table 3. Brush Wear Replacement Guide
103. INTRODUCTION
104. General
105. Description
106. Removal
107. Disassembly
108. Assembly
109. Installation
110. SPECIFICATIONS
111. TROUBLESHOOTING
112.
112.1. INTRODUCTION
112.1.1. GENERAL
112.1.2. DESCRIPTION
112.1.3. OPERATION
112.2. CHECKS AND ADJUSTMENTS
112.2.1. GENERAL
112.2.2. ECM CHECK
112.2.3. TRANSDUCER
112.2.4. CHAIN FOR STEERING CONTROL UNIT R40BH
112.2.5. ADJUSTMENTS
112.2.6. STEERING LINKAGE
112.2.7. TRANSDUCER AND BOARD
112.2.8. ADUSTING CHAIN FOR STEERING CONTROL UNIT R40BH
112.2.9. STEERING GENERATOR
112.2.10. STEERING PUMP AND MOTOR (R40EH and R40BH)
112.2.11. STEERING CONTROL UNIT AND GEARMOTOR ASSEMBLY, (R40EH, R40BH)
112.2.12. STEERING CONTROL UNIT (EARLY R40BH)
112.2.13. STEERING CYLINDER
112.2.14. STEERING AXLE
112.2.15. TRANSDUCER
112.2.16. TRANSDUCER BOARD
112.2.17. SHUT-OFF BOARD
112.3. TROUBLESHOOTING
113.
113.1. INTRODUCTION
113.1.1. GENERAL
113.1.2. DESCRIPTION
113.2. REPAIRS
113.2.1. REMOVAL AND DISASSEMBLY (R40BH, R40EH)
113.2.2. REMOVAL AND DISASSEMBLY (TWR-TRACTOR)
113.2.3. ASSEMBLY AND INSTALLATION
113.3. CHECKS AND ADJUSTMENTS
113.3.1. BRAKE ADJUSTMENT
113.3.2. ADJUSTMENT OF BRAKE FORCE
113.4. TROUBLESHOOTING
114.
114.1. INTRODUCTION
114.1.1. General
114.1.2. Description
114.1.3. Operation
114.1.4. General
114.1.5. Hydraulic Tank And Filter Assembly
114.1.6. Lift Pump And Motor Assembly
114.1.7. Attachment Control Valve
114.1.8. Lowering Control Valve Assembly
114.2. CHECKS AND ADJUSTMENTS
114.2.1. General
114.2.2. Air In The Hydraulic System
114.2.3. Adjusting The System Relief Valve
114.2.4. Adjusting Restriction Valves For Lowering Speeds
114.2.5. Adjusting The Attachment Relief Valve
114.3. TROUBLESHOOTING
114.3.1. General
114.4. SPECIFICATIONS
115.
116.
116.1. ELECTRICAL WARNING DEVICES
116.1.1. GENERAL
116.1.2. DESCRIPTION
116.1.3. REPLACEMENT
117.
117.1. INTRODUCTION
117.1.1. GENERAL
117.1.2. DESCRIPTION (See FIGURE 1.)
117.1.3. OPERATION
117.2. CHECKS, ADJUSTMENTS AND TEST PROCEDURES
117.2.1. GENERAL
117.2.2. ADJUSTMENTS
117.2.3. GENERAL
117.3. TEST PROCEDURES
117.3.1. CHECK FOR SHORT-CIRCUITS TO THE FRAME
117.3.2. GUIDANCE BUTTON, ALARM AND GUIDANCE LIGHT
117.3.3. CIRCUIT BOARD AND GUIDANCE BUTTON
117.3.4. STEERING GENERATOR
117.3.5. ELECTRONIC CONTROL MODULE (ECM)
117.3.6. CHECKING ECM POWER TRANSISTORS
117.3.7. TEST BUTTON, DISPLAY AND LEDS ON THE ECM
117.3.8. TRANSDUCER AND TRANSDUCER BOARD
117.3.9. GEAR MOTOR
117.3.10. GUIDANCE SENSORS
117.3.11. AUTOMATIC SHUT-OFF CIRCUIT
117.3.12. TEST POINT CHECKS
117.3.13. ECM SIGNAL CHECKS
118.
119.
120.
121.
121.1. INTRODUCTION
121.1.1. GENERAL
121.1.2. GENERAL
121.1.3. HOW TO REMOVE AND REPLACE THE BATTERY OR BATTERIES
121.1.4. STEERING GENERATOR
121.1.5. SENSORS
121.1.6. STEERING CONTROL UNIT AND GEARMOTOR ASSEMBLY
121.1.7. TRANSDUCER
121.1.8. TRANSDUCER BOARD
121.1.9. SHUT-OFF BOARD
121.1.10. CIRCUIT BOARD, GUIDANCE BUTTON, LIGHT AND ALARM (R40EH)
121.1.11. CIRCUIT BOARD, GUIDANCE BUTTON AND ALARM (R40BH)
121.2. ADJUSTMENTS
121.2.1. GENERAL
121.2.2. ADJUSTING STEERING LINKAGE
121.2.3. ADJUSTING TRANSDUCERS AND TRANSDUCER BOARDS
121.2.4. ADJUSTING CHAIN FOR STEERING CONTROL UNIT
121.2.5. SENSORS ADJUSTMENTS
122.
122.1. CHECKS AND ADJUSTMENTS
122.1.1. General
122.1.2. Control And Power Fuses
122.1.3. EV-100 Motor Controllers
122.1.4. Accelerator Potentiometer
122.1.5. Accelerator Control Forward And Reverse Switches
122.1.6. Main-Lift Control Potentiometer
122.1.7. Main-Lift Control Switches S1, S2, S3 S4)
122.1.8. Attachment Control Switches
122.1.9. Speed Potentiometers
122.1.10. Limit Switch LS-1 (Slow Speed)
122.1.11. Limit Switch LS-2 (Creep Speed)
122.1.12. Limit Switch LS-3 (Lift Speed)
122.1.13. Limit Switch LS-4 (Lowering Speed)
122.1.14. Limit Switch LS-6 And LS-7 (Loose Chain)
122.1.15. Limit Switch LS-8 (5 Steering)
122.1.16. Limit Switch LS-14 And LS-15 (Steer Indicator)
122.1.17. Solenoid Selector Valves
122.1.18. Lowering Solenoid Valves
122.1.19. General
122.1.20. Replacing The Accelerator Or Main-Lift Control Potentiometer
122.1.21. Replacing The Switches Of The Accelerator Or Main-Lift Control Assemblies
122.1.22. Replacing The Attachment Control Switches
122.1.23. Replacing The Key And Other Console Switches And Indicators
122.1.24. Replacing The Gate Switches
122.1.25. Replacing the Foot Switch
122.1.26. Replacing The Speed Potentiometers (Pots 1, 2 3)
122.1.27. Replacing The Limit Switches
122.1.28. Solenoid Valves
123.
123.1. INTRODUCTION
123.1.1. GENERAL
123.1.2. INDICATORS WITH METER MOVEMENT
123.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
123.2. CHECKS AND ADJUSTMENTS
123.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
123.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
123.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
123.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
123.2.5. LED DISPLAY WITH LIFT INTERRUPT
123.2.6. CHECKING CURTIS 933-1 METER
123.2.7. ADJUSTMENT OF CURTIS 933-1 METER
123.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
123.3. CURTIS DASH DISPLAY ASSEMBLY
123.3.1. Description/Features
123.3.2. Operation
123.3.3. Testing
123.4. REPAIRS
123.4.1. BATTERY INDICATORS
123.4.2. CONTROLLER FOR THE BATTERY INDICATOR
123.4.3. DISPLAY PANEL COMPONENTS
123.4.4. REPLACING SEM DISPLAY PANEL
123.4.5. SEM DISPLAY PANEL REMOVAL
124.
125.
125.1. INTRODUCTION
125.1.1. GENERAL
125.1.2. DESCRIPTION
125.1.3. REMOVAL AND DISASSEMBLY
125.1.4. REMOVAL OF MAST PARTS
125.1.5. ASSEMBLY AND INSTALLATION
125.2. CHECKS AND ADJUSTMENTS
125.2.1. ADJUSTMENT OF BOTTOM SIDE ROLLERS
125.3. TROUBLESHOOTING
126.
126.1. INTRODUCTION
126.1.1. General
126.1.2. Description
126.1.3. Attachment Removal
126.1.4. Disassembly
126.1.5. Assembly
126.1.6. Attachment Installation
126.2. CHECKS AND ADJUSTMENTS
126.2.1. Cab Wear Pads Adjustment
126.2.2. Free-Lift Upright Rollers Adjustment
126.2.3. Adjust Traverse Chains
126.2.4. Head Frame Adjustment
126.2.5. Carriage Clearance Adjustment
126.2.6. Worm Drive Alignement
126.2.7. Clutch Final Adjustment
126.2.8. Swing Chain Alignment
126.3. TROUBLESHOOTING
126.4. SPECIFICATIONS
127.
128.
128.1. INTRODUCTION
128.1.1. General
128.1.2. How To Move A Disabled Lift Truck
128.1.3. How To Put A Lift Truck On Blocks
128.2. MIANTENANCE SCHEDULE
128.3. MAINTENANCE PROCEDURES
128.4. EVERY 8 HOURS OR DAILY
128.4.1. Safety Labels
128.4.2. How To Make Checks With The Key Switch OFF
128.4.3. How To Make Checks With The Key Switch ON
128.5. EVERY 350 HOURS OR TWO MONTHS
128.5.1. Steer Axle
128.5.2. Hydraulic Tank Breather
128.5.3. Electrical Inspection
128.5.4. Mast And Lift Chains
128.5.5. Attachment
128.5.6. Hydraulic Pump Coupling
128.6. EVERY 2000 HOURS OR YEARLY
128.6.1. Wheel Bearings
128.6.2. Hydraulic System
128.6.3. Drive Units
128.6.4. Lift Chain Lubrication
128.6.5. Cable Anchors And Sheaves
128.6.6. Gate Hinges And Other Lubrication
128.7. GENERAL PROCEDURES
128.7.1. How To Charge The Battery Or Batteries
128.7.2. How To Change The Battery Or Batteries
128.7.3. Check For Leaks In The Lift System
128.7.4. How To Change Wheels And Tires
128.7.5. How To Check The PMT Circuit
128.7.6. How To Check SRO
128.8. BATTERY SPECIFICATIONS
129.
130.
130.1. FIGURE 1. HYDRAULIC SCHEMATIC
130.2. FIGURE 2. SCHEMATIC DIAGRAM (1 OF 2)
130.3. FIGURE 2. SCHEMATIC DIAGRAM (2 OF 2)
130.4. FIGURE 3. SCHEMATIC DIAGRAM – MAIN LIFT
130.5. FIGURE 4. WIRING DIAGRAM – MAIN FRAME (1 OF 3)
130.6. FIGURE 4. WIRING DIAGRAM – MAIN FRAME (2 OF 3)
130.7. FIGURE 4. WIRING DIAGRAM – MAIN FRAME (3 OF 3)
130.8. FIGURE 5. WIRING DIAGRAM – INSTR. PANEL, OPERATOR PLAT. UPRIGHT
130.9. FIGURE 6. CABLING DIAGRAM
130.10. FIGURE 7. WIRING DETAIL – CONTROL PANEL
130.11. FIGURE 8. WIRING DETAIL – MAIN FRAME
130.12. FIGURE 9. WIRING DETAIL – UPRIGHT
130.13. FIGURE 10. WIRING DETAIL – OPERATOR PLATFORM
130.14. FIGURE 11. WIRING DETAIL – INSTUMENT PANEL
130.15. FIGURE 12. WIRING DETAIL – WIRE GUIDANCE

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