Hyster A203 Parts Manual

$30.00

Type Of Manual: Parts Manual
Number of Pages: 440
Size: 13.6MB
Format: PDF

Category: Hyster Parts Manual PDF

Model List:
- A203

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. REPAIRS
33. OVERHEAD GUARD
34. Removal
35. Installation
36. HOOD AND SEAT ASSEMBLY
37. Removal
38. COUNTERWEIGHT
39. Removal
40. Installation
41. HYDRAULIC TANK
42. Inspection
43. Repairs, Small Leaks
44. Cleaning
45. SAFETY LABELS
46. BATTERY SPECIFICATIONS
47. INTRODUCTION
48. GENERAL
49. DESCRIPTION
50. OPERATION
51. REPAIRS
52. STEERING WHEEL AND COLUMN ASSEMBLY
53. TYPE A STEERING COLUMN ASSEMBLY
54. Removal And Disassembly
55. Assembly And Installation
56. TYPE A STEERING COLUMN
57. TYPE A STEERING COLUMN
58. TYPE B STEERING COLUMN
59. Removal And Disassembly
60. Assembly And Installation
61. TYPE B STEERING COLUMN
62. Disassembly of Steering Control Unit
63. Cleaning of Steering Control Unit
64. Assembly of Steering Control Unit
65. CHECKS AND ADJUSTMENTS
66. REMOVE AIR FROM THE SYSTEM
67. TROUBLESHOOTING
68. DC Motor Maintenance
69. Safety Precautions Maintenance and Repair
70. General
71. Brush and Commutator Inspection
72. Hydraulic Pump Motor and Traction Motor
73. Steering Pump Motor
74. Normal Commutator Surface
75. Commutator Problems
76. Brush Replacement
77. Stoning the Commutator
78. Motors Repair
79. Disassemble
80. Traction Motor and Hydraulic Pump Motor
81. Steering Pump Motor
82. Assemble
83. Traction Motor and Hydraulic Pump Motor
84. Steering Pump Motor
85. Brush Alignment, Traction and Hydraulic Motors
86. Tests for Damaged Field and Armature
87. Test for an Open Circuit in Armature
88. Test for Short Circuit in One Armature Winding
89. Test for Short Circuit to Armature Shaft
90. Test for Open Circuit in Field Coil
91. Test for Short Circuit in Field Coil
92. Test for Short Circuit between Field and Motor Case
93. Brush Holder Test
94. Troubleshooting
95. Table 1. Normal Commutator Surfaces
96. Table 2. Commutator Problems
97. Table 3. Brush Wear Replacement Guide
98. INTRODUCTION
99. GENERAL
100. DESCRIPTION
101. REMOVAL
102. Mount Type A
103. Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)
104. Mount Type B (R30DH Only)
105. DISASSEMBLY
106. ASSEMBLY
107. General
108. Installing The Spiral Bevel Pinion
109. Installing Thr Spiral Bevel Gear
110. INSTALLATION
111. Mount Type A
112. Mount Type B (A1.00-1.50XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)
113. Mount Type B (R30DH Only)
114. CHECKS AND ADJUSTMENTS
115. ADJUST THE BACKLASH AND TOOTH CONTACT
116. ADJUST BEARING CONTACT
117. TROUBLESHOOTING
118. INTRODUCTION
119. General
120. REPAIRS
121. Removal
122. Disassembly
123. Assembly
124. Installation
125. CHECKS AND ADJUSTMENTS
126. Check The Operation And Alignment Of The Steering System
127. Pinion And Gear Clearance
128. Adjusting Pinion And Gear Clearances
129. Adjustment For Correct Contact Pattern Of Gear Teeth
130. TROUBLESHOOTING
131.
131.1. INTRODUCTION
131.1.1. GENERAL
131.1.2. DESCRIPTION
131.1.3. STEERING WHEEL AND COLUMN ASSEMBLY
131.1.4. REMOVAL, STEERING CONTROL UNIT
131.1.5. INSTALLATION, STEERING CONTROL UNIT
131.2. POWER STEERING MOTOR AND PUMP
131.2.1. DESCRIPTION
131.2.2. REMOVAL AND DISASSEMBLY
131.2.3. ASSEMBLY AND INSTALLATION
131.2.4. REPAIRS, POWER STEERING PUMP
131.2.5. SEAL REPLACEMENT
131.3. HYDRAULIC STEERING MOTOR
131.3.1. DESCRIPTION
131.3.2. REPAIRS, HYDRAULIC STEERING MOTOR
131.4. CHECKS AND ADJUSTMENTS
131.4.1. POWER STEERING ADJUSTMENTS
131.5. TROUBLESHOOTING
132.
132.1. STEERING SYSTEM
132.1.1. GENERAL
132.1.2. DESCRIPTION
132.1.3. STEERING WHEEL AND COLUMN ASSEMBLY
132.2. POWER STEERING MOTOR AND PUMP
132.2.1. DESCRIPTION
132.2.2. REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)
132.2.3. REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)
132.2.4. REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)
132.2.5. REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)
132.2.6. REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)
132.2.7. ASSEMBLY AND INSTALLATION All models with a verticle mount except the J2.00-3.20XM (J40-65M)
132.2.8. ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)
132.2.9. ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)
132.2.10. REPAIRS, POWER STEERING PUMP
132.3. HYDRAULIC STEERING MOTOR
132.3.1. DESCRIPTION
132.3.2. REPAIRS, HYDRAULIC STEERING MOTOR
132.4. CHECKS AND ADJUSTMENTS
132.4.1. AIR IN THE STEERING SYSTEM
132.4.2. CHECK STEERING PRESSURE
132.4.3. CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)
132.4.4. CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS
132.5. TROUBLESHOOTING
133.
133.1. INTRODUCTION
133.1.1. GENERAL
133.1.2. DESCRIPTION AND OPERATION
133.2. REPAIRS
133.2.1. MASTER CYLINDER, EARLY MODELS
133.2.2. MASTER CYLINDER, LATE MODELS
133.2.3. SERVICE AND PARKING BRAKES
133.3. CHECKS AND ADJUSTMENTS
133.3.1. REMOVE THE AIR FROM THE BRAKE SYSTEM
133.3.2. ADJUST THE SERVICE BRAKES
133.3.3. ADJUST THE BRAKE PEDAL, EARLY MODELS
133.3.4. ADJUST THE BRAKE PEDAL, LATE MODELS
133.3.5. ADJUST THE PARKING BRAKE
133.4. TROUBLESHOOTING
134.
134.1. INTRODUCTION
134.1.1. GENERAL
134.1.2. DESCRIPTION
134.2. CONTROL VALVE
134.2.1. DESCRIPTION
134.2.2. OPERATION
134.2.3. REPAIRS
134.2.4. CHECKS AND ADJUSTMENTS
134.3. HYDRAULIC PUMP
134.3.1. DESCRIPTION
134.3.2. REPAIRS
134.4. TROUBLESHOOTING (HYDRAULIC PUMP)
134.5. TROUBLESHOOTING (CONTROL VALVE)
134.6. SPECIFICATIONS
135.
136.
136.1. INTRODUCTION
136.1.1. GENERAL
136.2. DESCRIPTION
136.2.1. GENERAL
136.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
136.2.3. LED DISPLAY PANEL
136.2.4. LX SERIES DISPLAY PANEL
136.2.5. ZX SERIES DISPLAY PANELS
136.3. CHECKS AND ADJUSTMENTS
136.3.1. GENERAL
136.4. REPLACEMENT
136.4.1. GENERAL
136.4.2. METER REPLACEMENT
136.4.3. SENDER REPLACEMENT
136.4.4. DISPLAY PANEL
136.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
136.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
136.5. SPECIFICATIONS
136.6. TROUBLESHOOTING
137.
137.1. ELECTRICAL WARNING DEVICES
137.1.1. GENERAL
137.1.2. DESCRIPTION
137.1.3. REPLACEMENT
138.
138.1. INTRODUCTION
138.1.1. GENERAL
138.1.2. LIFT TRUCK CONTROL
138.2. PRINCIPLES OF OPERATION
138.2.1. The Silicon Controlled Rectifier (SCR)
138.3. TABLE 1. PIN ARRANGEMENT AND FUNCTION FOR THE LOGIC BOX PLUG
138.3.1. TABLE 1. PIN ARRANGEMENT AND FUNCTION FOR THE LOGIC BOX PLUG
138.3.2. CONTACTORS
138.3.3. CIRCUIT PROTECTION
138.3.4. SEQUENCE OF OPERATION
139.
139.1. INTRODUCTION
139.1.1. GENERAL
139.1.2. THE LOGIC BOX
139.1.3. TABLE 1. PIN ARRANGEMENT AND FUNCTIONS FOR THE LOGIC BOX PLUG
139.1.4. ADJUSTMENTS
139.2. REPAIRS
139.2.1. CHECK THE SCRs
139.2.2. THE LC CIRCUIT
139.2.3. CONTACTORS
139.2.4. CONTACTORS REPAIR
139.2.5. CONTROL SWITCHES
139.3. TORQUE SPECIFICATIONS
140.
140.1. INTRODUCTION
140.1.1. General
140.2. SRO CIRCUIT AND FAULT SENSOR
140.2.1. Static Return To Off (Sro) Circuit
140.2.2. Fault Sensor
140.2.3. Checking For The Correct Operation
140.3. TROUBLESHOOTING
140.3.1. General Procedures
140.3.2. Fault Number 1. The Direction Contactors Will Not Close For Operation In Either Direction
140.3.3. Fault Number 2. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close And Then Immediately Open.
140.3.4. Fault Number 3. The Lift Truck Will Not Move In Either Direction. The Direction Contactor Closes Normally And Then Opens.
140.3.5. Fault Number 4. The Lift Truck Will Not Move In Either Direction. Both Direction Contactors Close.
140.3.6. Fault Number 5. One Direction Contactors Will Not Close. The Traction Circuit Operates Normally In Only One Direction.
140.3.7. Fault Number 6. Contactor 1a Will Not Energize. The Other Operations Of The Lift Truck Are Normal.
140.3.8. Fault Number 7. Plugging Problems
140.3.9. Fault Number 8. Hydraulic Control Problems
140.4. Table 1. Pin Arrangement And Functions For The Logic Box Plug
141.
141.1. INTRODUCTION
141.1.1. GENERAL
141.1.2. INDICATORS WITH METER MOVEMENT
141.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
141.2. CHECKS AND ADJUSTMENTS
141.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
141.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
141.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
141.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
141.2.5. LED DISPLAY WITH LIFT INTERRUPT
141.2.6. CHECKING CURTIS 933-1 METER
141.2.7. ADJUSTMENT OF CURTIS 933-1 METER
141.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
141.3. CURTIS DASH DISPLAY ASSEMBLY
141.3.1. Description/Features
141.3.2. Operation
141.3.3. Testing
141.4. REPAIRS
141.4.1. BATTERY INDICATORS
141.4.2. CONTROLLER FOR THE BATTERY INDICATOR
141.4.3. DISPLAY PANEL COMPONENTS
141.4.4. REPLACING SEM DISPLAY PANEL
141.4.5. SEM DISPLAY PANEL REMOVAL
142.
143.
143.1. INTRODUCTION
143.1.1. GENERAL
143.1.2. MAST WELDMENTS
143.1.3. CARRIAGE
143.1.4. MAST MOUNTS
143.2. VISTA TWO-STAGE MAST
143.2.1. DESCRIPTION AND OPERATION
143.3. VISTA FREE-LIFT MAST
143.3.1. DESCRIPTION
143.3.2. OPERATION
143.4. VISTA THREE-STAGE MAST
143.4.1. DESCRIPTION
143.4.2. OPERATION
143.5. VISTA FOUR-STAGE MAST
143.5.1. DESCRIPTION
143.5.2. OPERATION
144.
144.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
144.2. INTRODUCTION
144.2.1. GENERAL
144.2.2. CARRIAGE
144.2.3. REMOVAL FROM THE LIFT TRUCK
144.2.4. DISASSEMBLY
144.2.5. CLEANING AND INSPECTION
144.2.6. ASSEMBLY
144.2.7. INSTALLATION
144.3. LIFT CYLINDERS
144.3.1. DESCRIPTION
144.3.2. LOWERING CONTROL VALVE
144.3.3. REMOVAL OF THE LIFT CYLINDERS WITHOUT REMOVING THE MAST
144.3.4. DISASSEMBLY
144.3.5. ASSEMBLY
144.3.6. INSTALLATION OF THE LIFT CYLINDERS INTO THE MASTS
144.3.7. TILT CYLINDER
144.3.8. DESCRIPTION
144.3.9. REMOVAL
144.3.10. DISASSEMBLY
144.3.11. CLEANING
144.3.12. ASSEMBLY
144.3.13. INSTALLATION
144.3.14. SIDE-SHIFT CARRIAGE
144.4. CHECKS AND ADJUSTMENTS
144.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
144.4.2. ADJUSTMENT OF THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
144.4.3. LIFT CHAIN ADJUSTMENTS
144.4.4. MAST ADJUSTMENTS
144.4.5. CARRIAGE ADJUSTMENT
144.4.6. SIDE-SHIFT CYLINDER ADJUSTMENT
145.
146.
146.1. INTRODUCTION
146.1.1. GENERAL
146.1.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
146.1.3. HOW TO MOVE A DISABLED LIFT TRUCK
146.1.4. How To Tow A Lift Truck
146.1.5. HOW TO PUT A LIFT TRUCK ONTO BLOCK
146.1.6. How To Raise The Load Wheels
146.1.7. How To Raise The Steer Wheels
146.2. MAINTENANCE SCHEDULE
146.3. TABLE 1. MAINTENANCE SCHEDULE
146.4. MAINTENANCE PROCEDURES
146.5. EVERY 8 HOURS OR DAILY
146.5.1. CHECKS BEFORE OPERATION
146.5.2. CHECK THE OPERATION
146.6. EVERY 350 HOURS OR TWO MONTHS
146.6.1. HYDRAULIC TANK BREATHER
146.6.2. WHEEL NUT TORQUES
146.6.3. MDU (SPETH)
146.6.4. MDU (HURTH)
146.6.5. LIFT CHAINS
146.6.6. SAFETY LABELS
146.6.7. BRAKE FLUID
146.6.8. OTHER LUBRICATION
146.6.9. ELECTRICAL INSPECTION
146.7. HOURS OR YEARLY
146.7.1. HYDRAULIC SYSTEM
146.7.2. BRAKE SHOES
146.7.3. STEERING SYSTEM
146.7.4. MDU (SPETH)
146.7.5. MDU (HURTH)
146.7.6. ADJUST THE SERVICE BRAKES

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