Hyster C108 Service Manual – PDF DOWNLOAD
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Hyster C108 Service Manual – PDF DOWNLOAD
Language : English
Pages : 303
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Hyster C108 Service Manual – PDF DOWNLOAD
1600485......................................................................................................................................... 1 STEERING SYSTEMS FOR ELECTRICAL LIFT TRUCKS................................................................................................. 1 GENERAL................................................................................................................................. 1 DESCRIPTION............................................................................................................................. 3 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................................................... 4 Removal Of The Assembly Components.................................................................................................. 4 Installation Of The Assembly Components............................................................................................. 8 POWER STEERING MOTOR AND PUMP............................................................................................................... 9 DESCRIPTION............................................................................................................................. 9 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM), N30XMH.............................. 9 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL)....................................................................................... 9 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)........................................................................................ 10 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)........................................................................................ 12 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)...................................................................................... 13 ASSEMBLY AND INSTALLATION {All models with a vertical mount except the J2.00-3.20XM (J40-65XM)}......................................... 13 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)...................................................................................... 13 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (25-40XMS)..................................................................................... 16 REPAIRS, POWER STEERING PUMP............................................................................................................ 17 Seal Replacement.................................................................................................................... 18 HYDRAULIC STEERING MOTOR.................................................................................................................... 18 DESCRIPTION............................................................................................................................. 18 REPAIRS, HYDRAULIC STEERING MOTOR....................................................................................................... 19 Removal............................................................................................................................. 19 Disassembly ........................................................................................................................ 19 Cleaning And Inspection............................................................................................................. 19 Assembly............................................................................................................................ 20 Installation, Hydraulic Steering Motor.............................................................................................. 21 CHECKS AND ADJUSTMENTS...................................................................................................................... 21 AIR IN THE STEERING SYSTEM.............................................................................................................. 21 CHECK STEERING PRESSURE................................................................................................................. 21 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)........................................................................... 23 CHECK OPTICAL ENCODER AND ACTIVATOR CIRCUITS............................................................................................ 23 TROUBLESHOOTING............................................................................................................................. 25 2200288......................................................................................................................................... 27 EV-100 MOTOR CONTROLLER REPAIRS AND ADJUSTMENTS............................................................................................. 27 GENERAL................................................................................................................................. 27 FUSES................................................................................................................................... 32 CONTROL CARD............................................................................................................................ 33 The Control Card Plugs.............................................................................................................. 35 HOW TO CHECK AN SCR..................................................................................................................... 35 The SCR Assembly.................................................................................................................... 36 Thermal Protector................................................................................................................... 36 How To Replace The SCR 1 Assembly................................................................................................... 36 THE "OFF" CIRCUIT FOR SCR 1............................................................................................................. 37 Check The Inductor Assembly......................................................................................................... 37 Check Suppressors For SCR 2 And SCR 5............................................................................................... 37 Check SCR 2 And SCR 5............................................................................................................... 38 Replace The SCR 2 And SCR 5......................................................................................................... 38 Check Capacitor C1.................................................................................................................. 39 DIODES D3 AND D4........................................................................................................................ 39 Check The Diodes D3 and D4.......................................................................................................... 39 Replacement, Diodes D3 and D4....................................................................................................... 39 MOTOR CURRENT SENSOR.................................................................................................................... 39 THE ELECTRONIC DRIVER MODULE............................................................................................................ 39 CONTACTORS.............................................................................................................................. 40 CONTACTOR REPAIR........................................................................................................................ 41 Removing A Contactor Assembly....................................................................................................... 41 Contactor Contacts.................................................................................................................. 41 Coil................................................................................................................................ 42 CONTROL CARD ADJUSTMENTS................................................................................................................ 44 "CREEP"............................................................................................................................. 44 "C/A" (Controlled Acceleration)..................................................................................................... 44 "C/L"............................................................................................................................... 44 "1A TIME"........................................................................................................................... 45 "PLUG".............................................................................................................................. 46 "F.W.P.U. and "F.W.D.O."............................................................................................................ 46 "REGEN C/L"......................................................................................................................... 46 "REGEN D.O."........................................................................................................................ 46 VOLTAGE ADJUSTMENTS, SCR CONTROL FOR HYDRAULIC PUMP..................................................................................... 46 2200289......................................................................................................................................... 50 INTRODUCTION................................................................................................................................ 50 General................................................................................................................................. 50 Lift Truck Control...................................................................................................................... 50 PRINCIPLES OF OPERATION..................................................................................................................... 51 The Silicon Controlled Rectifier (SCR).................................................................................................. 53 A Motor Circuit That Operates With Pulses............................................................................................... 54 The SCR 1 "OFF" Circuit................................................................................................................. 55 Induction Current From The Motor........................................................................................................ 59 The Logic Box........................................................................................................................... 59 SCR Control (Hydraulic Pump)............................................................................................................ 64 Contactors.............................................................................................................................. 65 Circuit Protection...................................................................................................................... 66 Warning Indicators...................................................................................................................... 66 Sequence of Operation................................................................................................................... 67 2200290......................................................................................................................................... 71 INTRODUCTION................................................................................................................................ 71 General................................................................................................................................. 71 "Static Return To OFF" (SRO) Circuit ................................................................................................... 74 Fault Detector.......................................................................................................................... 74 The Sequence of Operation (Traction Circuit)............................................................................................ 74 Checking for the Correct Operation...................................................................................................... 74 TROUBLESHOOTING............................................................................................................................. 76 General Procedures...................................................................................................................... 76 FAULT NEMBER 1. The Direction Contactors Will Not Close For Operation In Either Direction................................................... 77 FAULT NUMBER 2. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close and The Immediately Open (72-80............ 80 FAULT NUMBER 2A. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close and Then Immediately Open (36-............ 82 FAULT NUMBER 3. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close Normally................................... 84 FAULT NUMBER 4. The Lift Truck Will Only Move In One Direction. In The Other Direction, The Direction Contactor Closes And Then ............ 85 FAULT NUMBER 5. One Direction Contactor Will Not Close. The Traction Circuit Operates Normally In Only One Direction........................ 86 FAULT NUMBER 6. Contactor 1A Will Not Energize. The Other Operations Of The Lift Truck Are Normal. (36-48 Volt Lift Trucks Equi ............ 87 FAULT NUMBER 7. Plugging Problems (Lift Trucks Equipped With Only The Plugging Function).................................................... 88 FAULT NUMBER 8. Regenerative Braking Problems (Lift Trucks Equipped With Regenerative Braking).............................................. 88 FAULT NUMBER 9. The Hydraulic Pump Motor Will Not Operate When Any Hydraulic Hand Lever Is Moved From The Neutral Position. (SCR............ 89 FAULT NUMBER 10. The Hydraulic Pump Will Not Stop Operating When The Hydraulic Hand Levers Are Returned To The Neutral Position............. 91 FAULT NUMBER 11. The Hydraulic Pump Will Not Operate When One Hydraulic Hand Lever Is Moved For A Hydraulic Function. The Operat............ 92 FAULT NUMBER 12. Hydraulic Control Problems (Lift Trucks Equipped With A Hydraulic Pump Contactor).......................................... 93 REPAIRS AND ADJUSTMENTS..................................................................................................................... 94 Fuses................................................................................................................................... 94 Logic Box............................................................................................................................... 94 Check the Components of the "OFF" Circuit............................................................................................... 96 Contactors.............................................................................................................................. 98 Contactor Repair........................................................................................................................ 99 LED Panel Display.......................................................................................................................100 Control Switches........................................................................................................................101 "PLUG"..................................................................................................................................105 Current Limit...........................................................................................................................105 2200312.........................................................................................................................................107 INTRODUCTION................................................................................................................................107 GENERAL.................................................................................................................................107 SRO CIRCUIT AND PMT CIRCUIT (TRACTION CIRCUIT)..............................................................................................110 STATIC RETURN TO OFF (SRO) CIRCUIT......................................................................................................110 PULSE MONITOR TRIP (PMT)................................................................................................................110 THE SEQUENCE OF OPERATION (TRACTION CIRCUIT)............................................................................................110 CHECKING FOR THE CORRECT OPERATION......................................................................................................111 TROUBLESHOOTING.............................................................................................................................112 GENERAL PROCEDURES......................................................................................................................113 FAULT NUMBER 1. The Direction Contactors Will Not Close For Operation In Either Direction...........................................115 LIFT TRUCKS WITHOUT REGENERATIVE BRAKING....................................................................................................115 GENERAL PROCEDURES......................................................................................................................113 FAULT NUMBER 2. Lift Truck Will Not Move In Either Direction. The Direction Contactors Close And Then Immediately Open (PMT Fau....118 FAULT NUMBER 3. Lift Truck Will Not Move In Either Direction. The Direction Contactors Close Normally (No PMT Fault)................120 FAULT NUMBER 4. Lift Truck Will Not Move In One Direction. The Direction Contactors Close Normally (No PMT Fault)...................122 FAULT NUMBER 5. One Direction Contactor Will Not Close. Traction Circuit Operates Normally In Only One Direction...................122 FAULT NUMBER 6. Plugging Problems...................................................................................................123 FAULT NUMBER 7. Direction Contactors Close Normally. The Lift Truck Has Only Low Power Or Moves Slowly.............................124 FAULT NUMBER 8. Contactor 1a Will Not Energize. The Other Operations Of The Lift Truck Are Normal..................................125 FAULT NUMBER 1R. Regenerative Braking Contactor Does Not Close. The "forward" And "reverse" Contactors Will Close. The Lift Tr....126 LIFT TRUCKS EQUIPPED WITH REGENERATIVE BRAKING..............................................................................................126 GENERAL PROCEDURES......................................................................................................................113 FAULT NUMBER 2R. Lift Truck Will Not Move In Either Direction. The Direction Contactors Never Close. The Regenerative Braking ....127 FAULT NUMBER 3R. Lift Truck Will Not Move In One Direction. The Regenerative Braking Contactor Closes Normally. Direction Cont....129 FAULT NUMBER 4R. Lift Truck Will Not Move In Either Direction. The Regenerative Braking Contactor Closes. A Direction Contacto....130 FAULT NUMBER 5R. Lift Truck Will Not Move In Either Direction. The Regenerative Braking Contactor Closes. The Direction Contac....132 FAULT NUMBER 6R. One Direction Contactor Will Not Close. The Regenerative Braking Contactor Closes Normally. The Traction Circ....134 FAULT NUMBER 7R. Direction Contactors Close Normally. The Lift Truck Has Only Low Power Or Moves Slowly. The Regenerative Brak....136 FAULT NUMBER 8R. Contactor 1a Will Not Energize. The Other Operations Of The Lift Truck Are Normal.................................137 FAULT NUMBER 9R. The Field Weakening Contactor Will Not Energize (36-48 Volt Lift Trucks Only). The Other Operations Of The Lif....138 FAULT NUMBER 10R. Regenerative Braking And Plugging Problems........................................................................139 FAULT NUMBER 11R. The Hydraulic Pump Will Not Operate When Any Hydraulic Hand Lever Is Moved From The Neutral Position..............140 FAULT NUMBER 12R. The Hydraulic Pump Will Not Stop Operating When The Hydraulic Hand Levers Are Returned To The Neutral Position....141 FAULT NUMBER 13R. The Hydraulic Pump Will Not Operate When Only One Hydraulic Lever Is Moved From The Neutral Position. The Ope....142 2200460.........................................................................................................................................143 INTRODUCTION................................................................................................................................143 General.................................................................................................................................143 DESCRIPTION.................................................................................................................................143 Diagnostic Control Card.................................................................................................................143 Status Codes........................................................................................................................145 Hand Set................................................................................................................................145 Instrument Panel Display................................................................................................................146 Hourmeter Functions.................................................................................................................146 Battery Indicator Functions.........................................................................................................146 Control Card Connections................................................................................................................147 CHECKS AND ADJUSTMENTS......................................................................................................................153 General.................................................................................................................................153 Function Codes......................................................................................................................153 Connecting The Control Card For Bench Checks And Adjustments........................................................................154 Connecting The Hand Set To A Control Card Installed In A Lift Truck.................................................................155 Checking And Adjusting Function Settings................................................................................................155 General.............................................................................................................................155 How To Connect And Check Hand Set ..................................................................................................155 How To Check And Adjust Functions...................................................................................................155 Function Descriptions...............................................................................................................156 Traction Control Cards (EV-100/200 LXT-LX)..........................................................................................156 Pump Control Card (EV-100/200 LXP)..................................................................................................160 Dual Motor Traction Control Card (EV-100 LXM).......................................................................................161 Function Tables.........................................................................................................................164 REPAIRS.....................................................................................................................................177 General.................................................................................................................................177 Control Card Plugs......................................................................................................................177 TROUBLESHOOTING.............................................................................................................................178 General.................................................................................................................................178 2200464.........................................................................................................................................213 ELECTRICAL CHECKS AND ADJUSTMENTS FOR SitDrive) ELECTRICAL LIFT TRUCKS......................................................................213 GENERAL.................................................................................................................................213 CONTROL AND POWER FUSES.................................................................................................................218 CONTROL CARD ADJUSTMENTS................................................................................................................219 Adjusting Creep Speed, "CREEP'......................................................................................................221 Adjusting Controlled Acceleration, "C/A" ...........................................................................................221 Adjusting Current Limit, "C/L"......................................................................................................222 Adjust "1A TIME"....................................................................................................................223 Adjust 1A Drop Out, "1A D.O"........................................................................................................225 Adjust Plugging, "PLUG".............................................................................................................225 Ramp Start..........................................................................................................................225 Adjust Field Weakening Pick Up and Drop Out, "F.W.P.U." And "F.W.D.O."..............................................................225 Adjust "REGEN C/L" (Current Limit)..................................................................................................226 Adjust "REGEN D.O." (Drop Out)......................................................................................................226 PROPORTIONAL CONTROL (J25-35A Only).....................................................................................................229 SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS.................................................................................................230 SCR CONTROL, SINGLE PUMP MOTOR..........................................................................................................230 Accelerator Card (E-20-100B, J40-60AS Only).........................................................................................231 Circuit Description For Accelerator Card Used With A Seat Switch....................................................................232 Accelerator "START" (IC3)...........................................................................................................233 Accelertor "1A TIME" (IC2)..........................................................................................................233 Circuit Description For Accelerator Card Used With A Seat Brake.....................................................................233 Accelerator "START" (IC3)...........................................................................................................234 Accelerator "1A TIME" (IC1 and IC2).................................................................................................234 CHECK THE ACCELERTOR CARD...........................................................................................................234 ADJUSTING THE ACCELERATOR CARD......................................................................................................234 THE POTENTIOMETERS AND CONTOL SWITCHES..................................................................................................234 Steering Potentiometer (J25-35A Only)...............................................................................................234 Accelerator Potentiometer And Start Switch (E20-120XL And J25-60XL Only)............................................................236 Accelerator Potentiometer And Direction Switch......................................................................................237 Adjusting Start Switch..............................................................................................................238 "FORWARD" And "REVERSE" Switch (MONOTROL) (Earlier Production Lift Trucks)..........................................................238 Direction Switches (MONOTROL) (Later Production Lift Trucks)........................................................................239 "FORWARD" And "REVERSE" Switch (Steering Column)....................................................................................240 Hydraulic Pump Switch...............................................................................................................240 Replace The Key Switch..............................................................................................................240 Adjust The Seat Switch..............................................................................................................240 Adjust The Brake Switch.............................................................................................................241 Parking Brake Switch................................................................................................................241 Rocker Switch.......................................................................................................................242 HYDRAULIC PUMP SOFT START (E100-120B Only) (72/80 Volt Only)............................................................................243 8000293.........................................................................................................................................244 FIGURE 1. SCHEMATIC DIAGRAM, EV-100 MOTOR CONTROLLER, (AFTER NOVEMBER 1987).................................................................244 FIGURE 2. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITHOUT LIFT INTERRUPT AND SCR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER NOVEMBER ............246 FIGURE 3. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITHOUT LIFT INTERRUPT AND WITH CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTE............247 FIGURE 4. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITH LIFT INTERRUPT AND WITH SCR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER NOVEMBE............248 FIGURE 5. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITH LIFT INTERRUPT AND WITH CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER N............249 FIGURE 6. SCHEMATIC DIAGRAM, LED DISPLAY WITH LIFT INTERRUPT AND WITH SCR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER NOVEMBER 1987............250 FIGURE 7. WIRE DIAGRAM, CONTROL SWITCHES (AFTER NOVEMBER 1987)..............................................................................251 FIGURE 8. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITH CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR (AFTER NOVEMBER 1987).......................253 FIGURE 9. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITH REGENERATIVE BRAKING, SCR CONTROL FOR HYDRAULIC PUMP MOTOR AND FIELD WEAKEN............254 FIGURE 10. WIRE DIAGRAMS, BATTERY INDICATORS (AFTER NOVEMBER 1987)..........................................................................255 FIGURE 11. WIRE DIAGRAMS, BATTERY INDICATORS (AFTER NOVEMBER 1987)..........................................................................256 FIGURE 12. SCHEMATIC DIAGRAM, EV-100 MOTOR CONTROLLER WITH REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987).....................................257 FIGURE 13. SCHEMATIC DIAGRAM, EV-100 MOTOR CONTROLLER WITHOUT REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987)..................................259 FIGURE 14. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITH REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987)..........................................261 FIGURE 15. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITHOUT REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987).......................................263 FIGURE 16. WIRE DIAGRAM, CONTROL SWITCHES (BEFORE NOVEMBER 1987)............................................................................265 FIGURE 17. WIRE DIAGRAMS, BATTERY INDICATORS (BEFORE NOVEMBER 1987).........................................................................267 FIGURE 18. HYDRAULIC SCHEMATIC, ALL MODELS..................................................................................................268 8000314.........................................................................................................................................269 8000466.........................................................................................................................................281 FIGURE 1. EV-100 "LX" SERIES TRACTION SCHEMATIC DIAGRAM.....................................................................................282 FIGURE 2. EV-100 "LX" SERIES BATTERY INDICATOR W/O LIFT INTERRUPT W/PUMP MOTOR SCR CONTROL SCHEMATIC........................................283 FIGURE 3. EV-100 "LX" SERIES BATTERY INDICATOR W/O LIFT INTERRUPT W/O PUMP MOTOR SCR CONTROL SCHEMATIC......................................284 FIGURE 4. EV-100 "LX" SERIES BATTERY INDICATOR W/LIFT INTERRUPT W/PUMP MOTOR SCR CONTROL SCHEMATIC..........................................285 FIGURE 5. EV-100 "LX" SERIES BATTERY INDICATOR W/LIFT INTERRUPT, W/O PUMP MOTOR SCR CONTROL SCHEMATIC.......................................286 FIGURE 6. EV-100 "LX" SERIES W/BWI DISPLAY AND W/LIFT INTERRUPT - W/PUMP MOTOR SCR CONTROL SCHEMATIC........................................288 FIGURE 7. EV-100 "LX" SERIES WITH GE OR ITW DISPLAY W/LIFT INTERRUPT - W/O PUMP MOTOR SCR CONTROL SCHEMATIC.................................290 FIGURE 8. EV-100 "LX" SERIES W OR W/O "ON-DEMAND" STEERING WIRING DIAGRAM...................................................................292 FIGURE 9. EV-100 "LX" SERIES W/O REGEN OR FIELD WEAKENING AND W/O PUMP MOTOR SCR CONTROL WIRING DIAGRAM.....................................294 FIGURE 10. EV-100 "LX" SERIES W/REGEN AND/OR FIELD WEAKENING AND SCR PUMP WIRING DIAGRAM....................................................296 FIGURE 11. EV-100 "LX" SERIES BATTERY INDICATOR W/O LIFT INTERRUPT AND W/PUMP MOTOR SCR CONTROL WIRING DIAGRAM..............................297 FIGURE 12. EV-100 "LX" SERIES BATTERY INDICATOR W/LIFT INTERRUPT AND W/PUMP MOTOR SCR CONTROL AND W/LIFT INTERRUPT, WIRING DIAGR............298 FIGURE 13. EV-100 "LX" SERIES BATTERY INDICATOR W/AND W/O LIFT INTERRUPT W/O PUMP MOTOR SCR CONTROL WIRING DIAGRAM..........................300 FIGURE 14. EV-100 "LX" SERIES GE BATTERY INDICATOR W/BWI DISPLAY AND W/LIFT INTERRUPT W/PUMP MOTOR SCR CONTROL WIRING DIAGRAM...............301 FIGURE 15. EV-100 "LX" SERIES I.T.W. (LED) DASH DISPLAY WIRING DIAGRAM......................................................................302
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