Hyster A186 Parts Manual

Description

• Model List:
  • A186

• 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. THE MASTER DRIVE UNIT
• 30. GENERAL
• 31. DESCRIPTION
• 32. REMOVAL
• 33. CLEANING
• 34. INSTALLATION
• 35. IDLER GEAR ASSEMBLY
• 36. DESCRIPTION
• 37. REMOVAL AND DISASSEMBLY
• 38. CLEANING
• 39. ASSEMBLY AND INSTALLATION
• 40. MOTOR AND PINION ASSEMBLY
• 41. GENERAL
• 42. REMOVAL AND DISASSEMBLY
• 43. CLEANING
• 44. ASSEMBLY AND INSTALLATION
• 45. AXLE AND SECOND REDUCER GEAR ASSEMBLY
• 46. GENERAL
• 47. REMOVAL AND DISASSEMBLY
• 48. CLEANING
• 49. ASSEMBLY AND INSTALLATION
• 50. CHECKS AND ADJUSTMENTS
• 51. BEARING PRELOAD
• 52. TROUBLESHOOTING
• 53. SPECIFICATIONS
• 54. INTRODUCTION
• 55. General
• 56. Description
• 57. REPAIRS
• 58. Drive Chassis
• 59. Base Arm Assembly
• 60. Hydraulic Tank, R30CH
• 61. Hydraulic Tank, R30DH
• 62. Decal Replacement
• 63. INTRODUCTION
• 64. GENERAL
• 65. DESCRIPTION
• 66. REPAIRS
• 67. REMOVAL AND DISASSEMBLY
• 68. Cleaning
• 69. ASSEMBLY AND INSTALLATION
• 70. BRAKE SWITCH
• 71. CHECKS AND ADJUSTMENTS
• 72. TROUBLESHOOTING
• 73. INTRODUCTION
• 74. GENERAL
• 75. DESCRIPTION
• 76. OPERATION
• 77. Relief Valve
• 78. REPAIRS
• 79. REMOVAL
• 80. DISASSEMBLY
• 81. ASSEMBLY
• 82. INSTALLATION
• 83. CHECKS AND ADJUSTMENTS
• 84. CHECKING THE RELIEF PRESSURE OF THE RELIEF VALVE
• 85. Lift Trucks With Internal Combustion Engines
• 86. Electric Lift Trucks
• 87. Electric Lift Trucks With Adjustable Relief Valve
• 88. SPECIFICATIONS
• 89. TROUBLESHOOTING
• 90. INTRODUCTION
• 91. DESCRIPTION
• 92. OPERATION
• 93. REPLACEMENT
• 94. ADJUSTMENT
• 95. DC Motor Maintenance
• 96. Safety Precautions Maintenance and Repair
• 97. General
• 98. Brush and Commutator Inspection
• 99. Hydraulic Pump Motor and Traction Motor
• 100. Steering Pump Motor
• 101. Normal Commutator Surface
• 102. Commutator Problems
• 103. Brush Replacement
• 104. Stoning the Commutator
• 105. Motors Repair
• 106. Disassemble
• 107. Traction Motor and Hydraulic Pump Motor
• 108. Steering Pump Motor
• 109. Assemble
• 110. Traction Motor and Hydraulic Pump Motor
• 111. Steering Pump Motor
• 112. Brush Alignment, Traction and Hydraulic Motors
• 113. Tests for Damaged Field and Armature
• 114. Test for an Open Circuit in Armature
• 115. Test for Short Circuit in One Armature Winding
• 116. Test for Short Circuit to Armature Shaft
• 117. Test for Open Circuit in Field Coil
• 118. Test for Short Circuit in Field Coil
• 119. Test for Short Circuit between Field and Motor Case
• 120. Brush Holder Test
• 121. Troubleshooting
• 122. Table 1. Normal Commutator Surfaces
• 123. Table 2. Commutator Problems
• 124. Table 3. Brush Wear Replacement Guide
• 125.
• 125.1. INTRODUCTION
• 125.1.1. GENERAL
• 125.1.2. DESCRIPTION
• 125.1.3. OPERATION
• 125.2. CHECKS, ADJUSTMENTS AND TEST PROCEDURES
• 125.2.1. GENERAL
• 125.2.2. ADJUSTMENTS
• 125.2.3. SETUP PROCEDURES FOR EPS
• 125.2.4. TEST PROCEDURES
• 125.3. REPAIRS
• 125.3.1. STEERING GENERATOR
• 125.3.2. STEERING MOTOR AND SPEED REDUCER
• 125.3.3. LIMIT SWITCHES
• 125.3.4. STEERING POTENTIOMETER
• 125.3.5. SHUT-OFF BOARD
• 125.4. TROUBLESHOOTING
• 126.
• 126.1. INTRODUCTION
• 126.1.1. GENERAL
• 126.1.2. DESCRIPTION
• 126.2. REPAIRS
• 126.2.1. REMOVAL AND DISASSEMBLY (R40BH, R40EH)
• 126.2.2. REMOVAL AND DISASSEMBLY (TWR-TRACTOR)
• 126.2.3. ASSEMBLY AND INSTALLATION
• 126.3. CHECKS AND ADJUSTMENTS
• 126.3.1. BRAKE ADJUSTMENT
• 126.3.2. ADJUSTMENT OF BRAKE FORCE
• 126.4. TROUBLESHOOTING
• 127.
• 127.1. INTRODUCTION
• 127.1.1. GENERAL
• 127.1.2. DESCRIPTION AND OPERATION
• 127.2. REPAIRS
• 127.2.1. ELECTRIC BRAKE
• 127.2.2. BRAKE SWITCH
• 127.3. TROUBLESHOOTING
• 128.
• 128.1. INTRODUCTION
• 128.1.1. General
• 128.1.2. Description
• 128.2. REPAIRS
• 128.2.1. Pumps and Pump Motors
• 128.2.2. Selector Valve
• 128.2.3. Lift Control Valve
• 128.2.4. Lowering Control Valve
• 128.2.5. Attachment Control Valve
• 128.2.6. Rotating Actuator Valve
• 128.3. CHECKS AND ADJUSTMENTS
• 128.3.1. Adjusting the Main Relief Valve
• 128.3.2. Adjusting the Attachment Relief Valve
• 128.3.3. Adjusting the Relief Valve in the Selector Valve
• 128.3.4. Checking the Speed of the Standard Upright
• 128.3.5. Checking the Speed of the Three-Stage Upright
• 128.3.6. Checking for Inside Leaks on the Lift System
• 128.3.7. Checking the Load Check Valves
• 128.4. TROUBLESHOOTING
• 129.
• 130.
• 130.1. INTRODUCTION
• 130.1.1. GENERAL
• 130.2. PRINCIPLES OF OPERATION
• 130.2.1. LIFT TRUCK CONTROL
• 130.2.2. ELECTRONIC SPEED CONTROLS
• 130.2.3. THE CONTROL CARD FOR THE TRACTION CIRCUIT
• 130.2.4. THERMAL PROTECTION
• 130.2.5. THE 1A CIRCUIT
• 130.2.6. FIELD WEAKENING
• 130.2.7. RAMP START
• 130.2.8. ACCELERATOR CONTROL
• 130.2.9. CONTACTORS AND ELECTRONIC DRIVERS
• 130.2.10. CIRCUIT PROTECTION
• 130.2.11. SEQUENCE OF OPERATION
• 131.
• 131.1. INTRODUCTION
• 131.1.1. GENERAL
• 131.2. SRO CIRCUIT AND PMT CIRCUIT
• 131.2.1. STATIC RETURN TO OFF(SRO) CIRCUIT
• 131.2.2. PULSE MONITOR TRIP (PMT)
• 131.2.3. THE SEQUENCE OF OPERATION
• 131.3. TROUBLESHOOTING
• 131.3.1. GENERAL PROCEDURES
• 131.4. CHECKS AND REPAIRS
• 131.4.1. GENERAL
• 131.4.2. CHECK FOR THE CORRECT OPERATION
• 131.4.3. CONTROL AND POWER FUSES
• 131.4.4. CONTROL CARD
• 131.4.5. THE INDUCTOR AND CAPACITOR ASSEMBLY (THE OFF CIRCUIT FOR SCR 1)
• 131.4.6. MOTOR CURRENT SENSOR
• 131.4.7. THE ELECTRONIC DRIVER MODULE
• 131.4.8. CONTACTORS
• 131.4.9. CONTACTOR REPAIR
• 131.4.10. CHECK THE PMT CIRCUIT
• 132.
• 132.1. CHECKS AND ADJUSTMENTS
• 132.1.1. General
• 132.1.2. Adjustments
• 132.2. REPAIRS
• 132.2.1. Replacing The Accelerator Card
• 132.2.2. Replacing The Accelerator Potentiometer
• 132.2.3. Replacing The Main Hoist Control
• 132.2.4. Replacing The Ledex Card
• 132.2.5. Replacing The Attachment Switch
• 132.2.6. Replacing The Speed Reduction Potentiometers
• 132.2.7. Replacing The Power Disconnect Module
• 133.
• 133.1. INTRODUCTION
• 133.1.1. GENERAL
• 133.1.2. DESCRIPTION
• 133.1.3. OPERATION
• 133.1.4. CHECKS, ADJUSTMENTS AND TEST PROCEDURES
• 134.
• 134.1. INTRODUCTION
• 134.1.1. General
• 134.1.2. Steering Generator
• 134.1.3. Sensors
• 134.1.4. Steering Motor and Speed Reducer
• 134.1.5. Limit Switches
• 134.1.6. Steering Potentiometer
• 134.1.7. Shut-Off Board
• 134.1.8. Circuit Board, Guidance Button and Alarm
• 134.2. ADJUSTMENTS
• 134.2.1. General
• 134.2.2. Adjusting Steering Chain
• 134.2.3. Adjusting Limit Swithces
• 134.2.4. Adjusting Steering Potentiometer
• 134.2.5. Adjusting Sensors
• 135.
• 135.1. INTRODUCTION
• 135.1.1. GENERAL
• 135.1.2. INDICATORS WITH METER MOVEMENT
• 135.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
• 135.2. CHECKS AND ADJUSTMENTS
• 135.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
• 135.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
• 135.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
• 135.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
• 135.2.5. LED DISPLAY WITH LIFT INTERRUPT
• 135.2.6. CHECKING CURTIS 933-1 METER
• 135.2.7. ADJUSTMENT OF CURTIS 933-1 METER
• 135.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
• 135.3. CURTIS DASH DISPLAY ASSEMBLY
• 135.3.1. Description/Features
• 135.3.2. Operation
• 135.3.3. Testing
• 135.4. REPAIRS
• 135.4.1. BATTERY INDICATORS
• 135.4.2. CONTROLLER FOR THE BATTERY INDICATOR
• 135.4.3. DISPLAY PANEL COMPONENTS
• 135.4.4. REPLACING SEM DISPLAY PANEL
• 135.4.5. SEM DISPLAY PANEL REMOVAL
• 136.
• 137.
• 137.1. INTRODUCTION
• 137.1.1. General
• 137.1.2. Description
• 137.2. REPAIRS
• 137.2.1. Removal
• 137.2.2. Disassembly
• 137.2.3. Cleaning and Inspection
• 137.2.4. Assembly
• 137.2.5. Installation
• 137.3. CHECKS AND ADJUSTMENTS
• 137.3.1. Lift Chain Adjustments
• 137.3.2. Operators Platform
• 137.4. TROUBLESHOOTING
• 138.
• 138.1. INTRODUCTION
• 138.1.1. General
• 138.1.2. Description
• 138.1.3. Operation
• 138.2. REPAIRS
• 138.2.1. Removal
• 138.2.2. Disassembly
• 138.2.3. Assembly and Installation
• 138.3. CHECKS AND ADJUSTMENTS
• 138.3.1. Center Rollers on the Base Frame
• 138.3.2. Side Load Rollers on the Swing Head
• 138.3.3. Free-Lift Chain
• 138.3.4. Adjustment of the Traverse Chains
• 138.3.5. Adjustment of the Swing Speed
• 138.4. TROUBLESHOOTING
• 138.5. SPECIFICATIONS
• 139.
• 140.
• 140.1. INTRODUCTION
• 140.1.1. General
• 140.1.2. Moving a Disable Truck
• 140.1.3. Maintenance Schedule
• 140.2. MAINTENANCE PROCEDURES
• 140.2.1. Hydraulic Oil and Filter
• 140.2.2. Master Drive Unit
• 140.2.3. Lifting Chains
• 140.2.4. Upright Surfaces
• 140.2.5. Attachment Rollers
• 140.2.6. Steering Speed Reducer
• 140.2.7. Spindal Bearings of the Master Drive Unit
• 140.2.8. Steering and Traverse Chains
• 140.2.9. Electric Cable and Hose Sheaves
• 140.2.10. Roller Shafts of the Limit Switches
• 140.2.11. Battery
• 140.2.12. Changing the Battery
• 140.2.13. Contactors
• 140.2.14. Checking Motor Brushes
• 140.2.15. Brake System
• 141.
• 142.