Hyster B098 (E60-120B) Parts Manual

Description

• Model List:
  • B098 (E60-120B)

• 1. INTRODUCTION
• 2. GENERAL
• 3. DESCRIPTION
• 4. DISASSEMBLY AND ASSEMBLY
• 5. OVERHEAD GUARD
• 6. Removal
• 7. Installation
• 8. SEAT ASSEMBLY
• 9. COUNTERWEIGHT
• 10. Removal
• 11. Installation
• 12. HYDRAULIC TANK REPAIRS
• 13. Small Leaks
• 14. Large Leaks
• 15. Steam Method Of Cleaning
• 16. Chemical Solution Method of Cleaning
• 17. Other Methods
• 18. LABEL REPLACEMENT
• 19. INTRODUCTION
• 20. GENERAL
• 21. LEAD-ACID BATTERIES
• 22. SPECIFIC GRAVITY
• 23. THE CHEMICAL REACTION IN A CELL
• 24. ELECTRICAL TERMS
• 25. HOW TO SELECT THE BATTERY
• 26. VOLTAGE OF A BATTERY
• 27. THE BATTERY AS A COUNTERWEIGHT
• 28. BATTERY RATINGS
• 29. Kilowatt-Hours
• 30. BATTERY MAINTENANCE
• 31. SAFETY PROCEDURES
• 32. MAINTENACE RECORDS
• 33. THE NEW BATTERY
• 34. HOW TO CLEAN THE BATTERY
• 35. HOW TO ADD WATER
• 36. THE HYDROMETER
• 37. BATTERY TEMPERATURE
• 38. CHARGING THE BATTERY
• 39. Types Of Battery Charges
• 40. Methods Of Charging
• 41. Troubleshooting The Charger
• 42. How To Know When The Battery Is Fully Charged
• 43. WHERE TO CHARGE THE BATTERIES
• 44. Equipment Needed
• 45. BATTERY CONNECTORS
• 46. BATTERY CARE
• 47. INTRODUCTION
• 48. General
• 49. Description
• 50. REPAIRS
• 51. Removal Of The Speed Reducer And Differential
• 52. Disassembly
• 53. Assembly
• 54. Installation Of The Drive Assembly
• 55. TROUBLESHOOTING
• 56. INTRODUCTION
• 57. General
• 58. Description
• 59. REPAIRS
• 60. Removal
• 61. Installation
• 62. Axle Housing For S30-100E And S40-50F Lift Trucks
• 63. Wheels And Tires
• 64. TROUBLESHOOTING
• 65. SPECIFICATIONS
• 66. INTRODUCTION
• 67. GENERAL
• 68. DESCRIPTION
• 69. OPERATION
• 70. REPAIRS
• 71. STEERING WHEEL AND COLUMN ASSEMBLY
• 72. TYPE A STEERING COLUMN ASSEMBLY
• 73. Removal And Disassembly
• 74. Assembly And Installation
• 75. TYPE A STEERING COLUMN
• 76. TYPE A STEERING COLUMN
• 77. TYPE B STEERING COLUMN
• 78. Removal And Disassembly
• 79. Assembly And Installation
• 80. TYPE B STEERING COLUMN
• 81. Disassembly of Steering Control Unit
• 82. Cleaning of Steering Control Unit
• 83. Assembly of Steering Control Unit
• 84. CHECKS AND ADJUSTMENTS
• 85. REMOVE AIR FROM THE SYSTEM
• 86. TROUBLESHOOTING
• 87. INTRODUCTION
• 88. GENERAL
• 89. DESCRIPTION
• 90. REPAIRS
• 91. STEERING AXLES WITH STUB SHAFT MOUNTS
• 92. Removal
• 93. Installation
• 94. ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS
• 95. Removal
• 96. Installation
• 97. ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)
• 98. Removal
• 99. Installation
• 100. WHEELS AND HUBS
• 101. Removal and Disassembly
• 102. Cleaning
• 103. Assembly And Installation
• 104. SPINDLES, BEARING AND TIE RODS
• 105. Removal And Disassembly
• 106. Cleaning
• 107. Assembly And Installation
• 108. STEERING CYLINDER
• 109. Removal And Disassembly
• 110. Cleaning
• 111. Assembly And Installation
• 112. CHECKS AND ADJUSTMENTS
• 113. STEERING CYLINDER
• 114. CENTER PIVOT OR RUBBER MOUNTS
• 115. SPINDLE AND HUB
• 116. TROUBLESHOOTING
• 117. INTRODUCTION
• 118. GENERAL
• 119. DESCRIPTION
• 120. REPAIRS
• 121. REMOVAL AND DISASSEMBLY
• 122. CLEANING
• 123. ASSEMBLY
• 124. CHECKS AND ADJUSTMENTS
• 125. INTRODCUTION
• 126. General
• 127. Description and Operation
• 128. REPAIRS
• 129. Removal and Disassembly
• 130. Cleaning
• 131. Inspection
• 132. Assembly and Installation
• 133. CHECKS AND ADJUSTMENTS
• 134. Manual Adjustment for the Service Brakes
• 135. Removing the Air from the Brake System
• 136. TROUBLESHOOTING
• 137. INTRODUCTION
• 138. DESCRIPTION
• 139. OPERATION
• 140. Flow Control Valve
• 141. Relief Valve
• 142. REPAIRS
• 143. REMOVAL
• 144. DISASSEMBLY
• 145. CLEANING
• 146. INSPECTION
• 147. ASSEMBLY
• 148. INSTALLATION
• 149. CHECKS AND ADUSTMENTS
• 150. CHECK THE OUTPUT OF THE PUMP
• 151. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
• 152. TROUBLESHOOTING
• 153. INTRODUCTION
• 154. GENERAL
• 155. DESCRIPTION
• 156. OPERATION
• 157. Relief Valve
• 158. REPAIRS
• 159. REMOVAL
• 160. DISASSEMBLY
• 161. ASSEMBLY
• 162. INSTALLATION
• 163. CHECKS AND ADJUSTMENTS
• 164. CHECKING THE RELIEF PRESSURE OF THE RELIEF VALVE
• 165. Lift Trucks With Internal Combustion Engines
• 166. Electric Lift Trucks
• 167. Electric Lift Trucks With Adjustable Relief Valve
• 168. SPECIFICATIONS
• 169. TROUBLESHOOTING
• 170. DC Motor Maintenance
• 171. Safety Precautions Maintenance and Repair
• 172. General
• 173. Brush and Commutator Inspection
• 174. Hydraulic Pump Motor and Traction Motor
• 175. Steering Pump Motor
• 176. Normal Commutator Surface
• 177. Commutator Problems
• 178. Brush Replacement
• 179. Stoning the Commutator
• 180. Motors Repair
• 181. Disassemble
• 182. Traction Motor and Hydraulic Pump Motor
• 183. Steering Pump Motor
• 184. Assemble
• 185. Traction Motor and Hydraulic Pump Motor
• 186. Steering Pump Motor
• 187. Brush Alignment, Traction and Hydraulic Motors
• 188. Tests for Damaged Field and Armature
• 189. Test for an Open Circuit in Armature
• 190. Test for Short Circuit in One Armature Winding
• 191. Test for Short Circuit to Armature Shaft
• 192. Test for Open Circuit in Field Coil
• 193. Test for Short Circuit in Field Coil
• 194. Test for Short Circuit between Field and Motor Case
• 195. Brush Holder Test
• 196. Troubleshooting
• 197. Table 1. Normal Commutator Surfaces
• 198. Table 2. Commutator Problems
• 199. Table 3. Brush Wear Replacement Guide
• 200.
• 200.1. INTRODUCTION
• 200.1.1. General
• 200.1.2. Description
• 200.2. REPAIRS
• 200.2.1. Parking Brake Assembly
• 200.3. ADJUSTMENTS
• 200.3.1. Adjustment of the Hand Brake Linkage
• 200.3.2. Adjustment of the Linkage for the Hand and Seat Brake
• 201.
• 201.1. INTRODUCTION
• 201.1.1. General
• 201.1.2. Description
• 201.1.3. The Control Valve
• 201.2. REPAIRS
• 201.2.1. Hydraulic Pump
• 201.2.2. Main Control Valve
• 201.2.3. Hydraulic Pump Contactor
• 201.2.4. Contactor Repair
• 201.3. CHECKS AND ADJUSTMENTS
• 201.3.1. Adjusting The Pressure Relief Valve
• 201.3.2. Adjustment Of The Control Linkage
• 201.3.3. Hydraulic Pump Switch
• 201.4. TROUBLESHOOTING
• 202.
• 203.
• 203.1. INTRODUCTION
• 203.1.1. GENERAL
• 203.2. PRINCIPLES OF OPERATION
• 203.2.1. LIFT TRUCK CONTROL
• 203.2.2. ELECTRONIC SPEED CONTROLS
• 203.2.3. THE CONTROL CARD FOR THE TRACTION CIRCUIT
• 203.2.4. THERMAL PROTECTION
• 203.2.5. THE 1A CIRCUIT
• 203.2.6. FIELD WEAKENING
• 203.2.7. RAMP START
• 203.2.8. ACCELERATOR CONTROL
• 203.2.9. CONTACTORS AND ELECTRONIC DRIVERS
• 203.2.10. CIRCUIT PROTECTION
• 203.2.11. SEQUENCE OF OPERATION
• 204.
• 204.1. INTRODUCTION
• 204.1.1. GENERAL
• 204.2. DESCRIPTION
• 204.2.1. GENERAL
• 204.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
• 204.2.3. LED DISPLAY PANEL
• 204.2.4. LX SERIES DISPLAY PANEL
• 204.2.5. ZX SERIES DISPLAY PANELS
• 204.3. CHECKS AND ADJUSTMENTS
• 204.3.1. GENERAL
• 204.4. REPLACEMENT
• 204.4.1. GENERAL
• 204.4.2. METER REPLACEMENT
• 204.4.3. SENDER REPLACEMENT
• 204.4.4. DISPLAY PANEL
• 204.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
• 204.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
• 204.5. SPECIFICATIONS
• 204.6. TROUBLESHOOTING
• 205.
• 205.1. ELECTRICAL WARNING DEVICES
• 205.1.1. GENERAL
• 205.1.2. DESCRIPTION
• 205.1.3. REPLACEMENT
• 206.
• 206.1. INTRODUCTION
• 206.1.1. GENERAL
• 206.2. SRO CIRCUIT AND PMT CIRCUIT
• 206.2.1. STATIC RETURN TO OFF(SRO) CIRCUIT
• 206.2.2. PULSE MONITOR TRIP (PMT)
• 206.2.3. THE SEQUENCE OF OPERATION
• 206.3. TROUBLESHOOTING
• 206.3.1. GENERAL PROCEDURES
• 206.4. CHECKS AND REPAIRS
• 206.4.1. GENERAL
• 206.4.2. CHECK FOR THE CORRECT OPERATION
• 206.4.3. CONTROL AND POWER FUSES
• 206.4.4. CONTROL CARD
• 206.4.5. THE INDUCTOR AND CAPACITOR ASSEMBLY (THE OFF CIRCUIT FOR SCR 1)
• 206.4.6. MOTOR CURRENT SENSOR
• 206.4.7. THE ELECTRONIC DRIVER MODULE
• 206.4.8. CONTACTORS
• 206.4.9. CONTACTOR REPAIR
• 206.4.10. CHECK THE PMT CIRCUIT
• 207.
• 207.1. INTRODUCTION
• 207.1.1. GENERAL
• 207.2. CONTROL FUNCTIONS AND ADJUSTMENTS
• 207.2.1. OSCILLATOR CIRCUIT
• 207.2.2. CONTROL CARD ADJUSTMENTS
• 207.2.3. PULSE MONITOR TRIP (PMT)
• 207.2.4. SRO CIRCUIT
• 207.2.5. THE SEQUENCE OF OPERATION
• 207.2.6. CHECKING FOR THE CORRECT OPERATION
• 207.3. TROUBLESHOOTING
• 207.3.1. GENERAL PROCEDURES
• 207.4. CHECKS AND REPAIRS
• 207.4.1. GENERAL
• 207.4.2. CONTROL AND POWER FUSES
• 207.4.3. CONTROL CARD
• 207.4.4. THE INDUCTOR AND CAPACITOR ASSEMBLY (THE OFF CIRCUIT FOR SCR 1)
• 207.4.5. MOTOR CURRENT SENSOR
• 207.4.6. THE ELECTRONIC DRIVER MODULE
• 207.4.7. FORWARD AND REVERSE CONTACTORS
• 207.4.8. CONTACTOR REPAIR
• 207.4.9. HYDRAULIC PUMP SOFT START
• 207.4.10. SCHEMATIC DIAGRAM, 36-48 VOLT LIFT TRUCKS
• 207.4.11. WIRING DIAGRAM, 36-48 VOLT LIFT TRUCKS
• 207.4.12. SCHEMATIC DIAGRAM, 72-80 VOLT LIFT TRUCKS
• 207.4.13. WIRING DIAGRAM, 72-80 VOLT LIFT TRUCKS
• 208.
• 209.
• 209.1. INTRODUCTION
• 209.1.1. GENERAL
• 209.1.2. INDICATORS WITH METER MOVEMENT
• 209.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
• 209.2. CHECKS AND ADJUSTMENTS
• 209.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
• 209.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
• 209.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
• 209.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
• 209.2.5. LED DISPLAY WITH LIFT INTERRUPT
• 209.2.6. CHECKING CURTIS 933-1 METER
• 209.2.7. ADJUSTMENT OF CURTIS 933-1 METER
• 209.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
• 209.3. CURTIS DASH DISPLAY ASSEMBLY
• 209.3.1. Description/Features
• 209.3.2. Operation
• 209.3.3. Testing
• 209.4. REPAIRS
• 209.4.1. BATTERY INDICATORS
• 209.4.2. CONTROLLER FOR THE BATTERY INDICATOR
• 209.4.3. DISPLAY PANEL COMPONENTS
• 209.4.4. REPLACING SEM DISPLAY PANEL
• 209.4.5. SEM DISPLAY PANEL REMOVAL
• 210.
• 210.1. INTRODUCTION
• 210.1.1. GENERAL
• 210.2. REPAIRS
• 210.2.1. CARRIAGE
• 210.2.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 210.2.3. INSTALLATION
• 210.3. CHECKS AND ADJUSTMENTS
• 210.3.1. CHECKING FOR LEAKS IN THE LIFT SYSTEM
• 210.3.2. ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
• 210.3.3. LIFT CHAIN ADJUSTMENTS
• 210.3.4. MAST ADJUSTMENTS
• 210.3.5. CARRIAGE ADJUSTMENT
• 210.4. TROUBLESHOOTING
• 211.
• 212.
• 212.1. INTRODUCTION
• 212.1.1. GENERAL
• 212.1.2. STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)
• 212.1.3. FULL FREE-LIFT MASTS
• 212.1.4. THREE-STAGE MASTS
• 212.1.5. FOUR-STAGE MASTS
• 212.1.6. SEQUENCE VALVE
• 213.
• 213.1. INTRODUCTION
• 213.1.1. GENERAL
• 213.2. VISTA TWO-STAGE MASTS
• 213.2.1. DESCRIPTION
• 213.2.2. OPERATION
• 213.3. VISTA THREE-STAGE MASTS
• 213.3.1. DESCRIPTION
• 213.3.2. OPERATION
• 213.3.3. SEQUENCE VALVE
• 214.
• 215.
• 215.1. INTRODUCTION
• 215.1.1. General
• 215.1.2. Moving A Disabled Lift Truck
• 215.2. MAINTENANCE SCHEDULE
• 215.3. MAINTENANCE PROCEDURES
• 215.3.1. Every 8 Hours or Daily
• 215.3.2. Every 350 Hours or Two Months
• 215.3.3. Every 2000 Hours or Yearly
• 215.4. WHEELS AND TIRES
• 215.5. CHANGING TIRES
• 215.6. BATTERY
• 215.6.1. CHANGING THE BATTERY
• 216.
• 217.
• 217.1. FIGURE 1. SCHEMATIC DIAGRAM WITH ACCELERATOR CARD
• 217.2. FIGURE 2. SCHEMATIC DIAGRAM WITH ACCELERATOR CARD AND SEAT BRAKE
• 217.3. FIGURE 3. WIRING DIAGRAM WITH ACCELERATOR CARD
• 217.4. FIGURE 4. WIRING DIAGRAM, 36/48 VOLT EV-1 CONTROL
• 217.5. FIGURE 5. SCHEMATIC DIAGRAM, 36/48 VOLT EV-1 CONTROL
• 217.6. FIGURE 6. WIRING DIAGRAM, 72/80 VOLT EV-1 CONTROL
• 217.7. FIGURE 7. SCHEMATIC DIAGRAM 72/80 VOLT EV-1 CONTROL
• 217.8. FIGURE 8. SCHEMATIC DIAGRAM, 36/48 VOLT EV-1W CONTROL
• 217.9. FIGURE 9. WIRING DIAGRAM, 36/48 VOLT EV-1W CONTROL
• 217.10. FIGURE 10. SCHEMATIC DIAGRAM, 72/80 VOLT EV-1W CONTROL
• 217.11. FIGURE 11. WIRING DIAGRAM, 72/80 VOLT EV-1W CONTROL
• 218.