Hyster E118 (R30FFAFF) Service Manual - Image 2

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Hyster E118 (R30FFAFF) Service Manual - Image 5

Hyster E118 (R30FFAFF) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 503
Size: 27.9MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- E118 (R30FFAFF)

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
33. Covers, Panels And Plates
34. R30EA-FS Caster And Caser Wheel
35. Description
36. Replacing Caster
37. Replacing Caster Wheels
38. Painting Instructions
39. Label Replacement
40. INTRODUCTION
41. DESCRIPTION
42. OPERATION
43. Flow Control Valve
44. Relief Valve
45. REPAIRS
46. REMOVAL
47. DISASSEMBLY
48. CLEANING
49. INSPECTION
50. ASSEMBLY
51. INSTALLATION
52. CHECKS AND ADUSTMENTS
53. CHECK THE OUTPUT OF THE PUMP
54. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
55. TROUBLESHOOTING
56. DC Motor Maintenance
57. Safety Precautions Maintenance and Repair
58. General
59. Brush and Commutator Inspection
60. Hydraulic Pump Motor and Traction Motor
61. Steering Pump Motor
62. Normal Commutator Surface
63. Commutator Problems
64. Brush Replacement
65. Stoning the Commutator
66. Motors Repair
67. Disassemble
68. Traction Motor and Hydraulic Pump Motor
69. Steering Pump Motor
70. Assemble
71. Traction Motor and Hydraulic Pump Motor
72. Steering Pump Motor
73. Brush Alignment, Traction and Hydraulic Motors
74. Tests for Damaged Field and Armature
75. Test for an Open Circuit in Armature
76. Test for Short Circuit in One Armature Winding
77. Test for Short Circuit to Armature Shaft
78. Test for Open Circuit in Field Coil
79. Test for Short Circuit in Field Coil
80. Test for Short Circuit between Field and Motor Case
81. Brush Holder Test
82. Troubleshooting
83. Table 1. Normal Commutator Surfaces
84. Table 2. Commutator Problems
85. Table 3. Brush Wear Replacement Guide
86. INTRODUCTION
87. GENERAL
88. DESCRIPTION
89. REMOVAL
90. Mount Type A
91. Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)
92. Mount Type B (R30DH Only)
93. DISASSEMBLY
94. ASSEMBLY
95. General
96. Installing The Spiral Bevel Pinion
97. Installing Thr Spiral Bevel Gear
98. INSTALLATION
99. Mount Type A
100. Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)
101. Mount Type B (R30DH Only)
102. CHECKS AND ADJUSTMENTS
103. ADJUST THE BACKLASH AND TOOTH CONTACT
104. ADJUST BEARING CONTACT
105. TROUBLESHOOTING
106.
107.
107.1. Power Steering
107.2. Safety Precautions Maintenance and Repair
107.3. General
107.4. EPS III
107.5. Description
107.6. EPS III
107.7. APS System
107.8. Checks and Adjustments
107.9. General
107.10. Checks, EPS III
107.11. Dipswitches, EPS III
107.12. LED Indicators, EPS III
107.13. Check Steering System for Correct Operation, EPS III
107.14. Check Slow Travel Speed, EPS III
107.15. Check High Lift Traction Shutoff, EPS III
107.16. Checks, APS
107.17. Dipswitches, APS
107.18. LED Indicators, APS
107.19. Adjustments
107.20. General
107.21. Steer Motor With Steering Chain Replacement, EPS III
107.22. Steer Motor With Steering Gear Replacement, APS
107.23. Return-to-Center Steering System
107.24. Tach Generator Steering System, EPS III
107.25. Slow Travel Adjustment, EPS III
107.26. Return-to-Center and Multiturn System, APS
107.27. Steering Chain Adjustment, EPS III
107.28. Repairs
107.29. RTC Steering System, EPS III
107.30. Command Potentiometer Replacement, EPS III
107.31. TGS System, EPS III
107.32. Tach Generator Replacement, EPS III
107.33. Feedback Potentiometer Replacement, EPS III
107.34. ECM Replacement, EPS III
107.35. Steer Motor Assembly and Steering Chain Replacement, EPS III
107.36. Typical Operating Voltages, EPS III
107.37. Steering Proximity Switch and Centering Proximity Switch, APS
107.38. Troubleshooting
107.39. EPS III
107.40. Table 1. LED Indicators
107.41. Table 2. Sensitivity Adjustment
107.42. Table 3. Typical Operating Voltages
108.
108.1. INTRODUCTION
108.1.1. GENERAL
108.1.2. DESCRIPTION AND OPERATION
108.2. REPAIRS
108.2.1. ELECTRIC BRAKE
108.2.2. BRAKE SWITCH
108.3. TROUBLESHOOTING
109.
109.1. INTRODUCTION
109.1.1. Description
109.2. REPAIRS
109.2.1. Hydraulic Pump
109.2.2. Control Valve
109.3. CHECKS AND ADJUSTMENTS
109.3.1. Relief Valve Adjustments
109.4. TROUBLESHOOTING
109.4.1. Hydraulic Pump
109.4.2. Control Valve
109.5. SPECIFICATIONS
110.
111.
111.1. INTRODUCTION
111.1.1. GENERAL
111.2. DESCRIPTION
111.2.1. GENERAL
111.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
111.2.3. LED DISPLAY PANEL
111.2.4. LX SERIES DISPLAY PANEL
111.2.5. ZX SERIES DISPLAY PANELS
111.3. CHECKS AND ADJUSTMENTS
111.3.1. GENERAL
111.4. REPLACEMENT
111.4.1. GENERAL
111.4.2. METER REPLACEMENT
111.4.3. SENDER REPLACEMENT
111.4.4. DISPLAY PANEL
111.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
111.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
111.5. SPECIFICATIONS
111.6. TROUBLESHOOTING
112.
113.
113.1. CHECKS AND ADJUSTMENTS
113.1.1. GENERAL
113.1.2. CONTROL AND POWER FUSES
113.1.3. EV-100 MOTOR CONTROLLER
113.1.4. ACCELERATOR POTENTIOMETER
113.1.5. FORWARD AND REVERSE SWITCHES
113.1.6. LIMIT SWITCH LS-1 AND LS-3 (Traction Cutout And Traction Override)
113.1.7. LOOSE CHAIN SWITCH
113.1.8. LIMIT SWITCH LS-2 (Lowering Speed, Travel Speed)
113.1.9. GENERAL
113.1.10. REPLACE THE ELECTRICAL PARTS OF THE STEERING, HYDRAULIC OR OPTIONAL GUIDANCE SYSTEMS
113.1.11. REPLACE THE ACCELERATOR POTENTIOMETER
113.1.12. REPLACE THE KEY AND OTHER CONSOLE SWITCHES AND INDICATOR LIGHTS
113.1.13. REPLACE SWITCHES IN THE DIRECTION/SPEED CONTROL
113.1.14. REPLACE THE LIMIT SWITCHES
114.
114.1. INTRODUCTION
114.1.1. General
114.1.2. Operation
114.2. CHECKS AND ADJUSTMENTS
114.2.1. General
114.2.2. Adjustments
115.
115.1. INTRODUCTION
115.1.1. GENERAL
115.1.2. STEERING MECHANISM
115.1.3. REPLACE GUIDANCE SWITCH, INDICATOR AND ALARM
115.1.4. REPLACE MDU POTENTIOMETER
115.1.5. REPLACE THE ECM
115.1.6. REPLACE THE STEERING CONTACTOR
115.1.7. REPLACE THE GEARMOTOR ASSEMBLY AND STEERING CHAIN
115.1.8. REPLACE THE SENSORS
116.
117.
117.1. INTRODUCTION
117.1.1. GENERAL
117.1.2. INDICATORS WITH METER MOVEMENT
117.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
117.2. CHECKS AND ADJUSTMENTS
117.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
117.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
117.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
117.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
117.2.5. LED DISPLAY WITH LIFT INTERRUPT
117.2.6. CHECKING CURTIS 933-1 METER
117.2.7. ADJUSTMENT OF CURTIS 933-1 METER
117.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
117.3. CURTIS DASH DISPLAY ASSEMBLY
117.3.1. Description/Features
117.3.2. Operation
117.3.3. Testing
117.4. REPAIRS
117.4.1. BATTERY INDICATORS
117.4.2. CONTROLLER FOR THE BATTERY INDICATOR
117.4.3. DISPLAY PANEL COMPONENTS
117.4.4. REPLACING SEM DISPLAY PANEL
117.4.5. SEM DISPLAY PANEL REMOVAL
118.
119.
119.1. INTRODUCTION
119.1.1. General
119.1.2. Upright Weldments
119.1.3. Carriages (N40-50EA Only)
119.1.4. Operator Platform (R30E/EA/EA-FS Only)
119.2. VISTA TWO-STAGE UPRIGHTS
119.2.1. Description
119.2.2. Operation
119.3. VISTA THREE-STAGE UPRIGHTS
119.3.1. Description
119.3.2. Operation
120.
120.1. INTRODUCTION
120.1.1. General
120.2. REPAIRS
120.2.1. Replacement (N40-50ER)
120.2.2. Replacement (R30E/EA/EA-FS)
120.2.3. Carriage Or Operator Platform
120.3. TWO-STAGE UPRIGHT
120.3.1. Removal
120.3.2. Disassembly
120.3.3. Cleaning And Inspection
120.3.4. Lift Cylinders
120.3.5. Assembly
120.3.6. Installation
120.4. THREE-STAGE UPRIGHT
120.4.1. Removal
120.4.2. Disassembly
120.4.3. Cleaning And Inspection
120.4.4. Lift Cylinders
120.4.5. Assembly
120.4.6. Installation
120.5. GENERAL PROCEDURES
120.5.1. Replacing Load Wheels
120.6. CHECKS AND ADJUSTMENTS
120.6.1. Checking For Leaks In The Lift System
120.6.2. Lift Chain Adjustments
120.6.3. Upright Adjustments
120.6.4. Carriage Or Operator Platform Adjustment
120.7. TROUBLESHOOTING
121.
122.
122.1. INTRODUCTION
122.1.1. GENERAL
122.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
122.1.3. How To Tow The Lift Truck
122.1.4. HOW TO PUT A LIFT TRUCK ON BLOCKS
122.1.5. How To Raise Drive Tire
122.1.6. How To Raise Load Wheels
122.2. MAINTENANCE SCHEDULE
122.3. MAINTENANCE PROCEDURES- EVERY 8 HOURS OR DAILY
122.3.1. HOW TO MAKE CHECKS WITH KEY SWITCH OFF
122.3.2. HOW TO MAKE CHECKS WITH THE KEY SWITCH ON
122.4. EVERY 350 HOURS OR TWO MONTHS
122.4.1. HYDRAULIC TANK BREATHER
122.4.2. ELECTRICAL INSPECTION
122.4.3. SAFETY LABELS
122.4.4. CHECK FOR LEAKS IN THE LIFT SYSTEM
122.4.5. LIFT CHAINS
122.5. EVERY 2000 HOURS OR YEARLY
122.5.1. MASTER DRIVE UNIT
122.5.2. STEERING CHAIN
122.5.3. WHEELS AND BEARINGS
122.5.4. HOW TO CHANGE THE HYDRAULIC OIL AND FILTER
122.5.5. ELECTRICAL CABLE SHEAVES
122.5.6. PALLET CLAMP
122.5.7. LIMIT SWITCH ROLLERS AND OTHER LUBRICATION
122.6. GENERAL PROCEDURES
122.6.1. HOW TO CHARGE THE BATTERY
122.6.2. HOW TO CHANGE THE BATTERY
122.6.3. HOW TO CHANGE WHEELS AND TIRES
122.7. BATTERY SPECIFICATIONS
123.
123.1. BATTERY SPECIFICATIONS
123.2. TRANSISTOR CONTROLLER ADJUSTMENT POINTS
123.3. EV100 TRACTION CARD SETTINGS
123.4. MASTER DRIVE UNIT
123.5. SYSTEM II ELECTRONIC CONTROL MODULE (ELECTRIC POWER STEERING)
123.6. TERMINAL AND PIN ARRANGEMENTS FOR THE EV100 CONTROL CARD
123.7. TERMINAL AND PIN ARRANGEMENTS FOR THE CURTIS 1204X 4406
123.8. SYSTEM II ELECTRONIC CONTROL MODULE (WIRE GUIDANCE)
123.9. TRANSISTOR RESISTANCE
123.10. SYSTEM II WIRE GUIDANCE SPECIFICATIONS
123.11. HYDRAULIC SYSTEM
123.12. TORQUE SPECIFICATIONS
124.
124.1. FIGURE 1. HYDRAULIC SCHEMATIC
124.2. FIGURE 2. SCHEMATIC DIAGRAM WITHOUT WIRE GUIDANCE
124.3. FIGURE 3. WIRING DIAGRAM-MOTOR COMPARTMENT-WITHOUT WIRE GUIDANCE
124.4. FIGURE 4. WIRING DIAGRAM-OPERATORS PLATFORM-WITHOUT WIRE GUIDANCE
124.5. FIGURE 5. SCHEMATIC DIAGRAM WITH WIRE GUIDANCE
124.6. FIGURE 6. WIRING DIAGRAM-MOTOR COMPARTMENT-WITH WIRE GUIDANCE
124.7. FIGURE 7. WIRING DIAGRAM-OPERATORS PLATFORM-WITH WIRE GUIDANCE
124.8. FIGURE 8. WIRING DIAGRAM-OPTIONAL EQUIPMENT
124.9. FIGURE 9. CABLING AND DETAIL DIAGRAM
124.10. FIGURE 10. CABLING AND DETAIL DIAGRAM
124.11. FIGURE 11. WIRE GUIDANCE AND DETAIL DIAGRAM

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