Hyster B114 (E20-30BS) Parts Manual

Description

• Model List:
  • B114 (E20-30BS)

• 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. OPERATION
• 60. REPAIRS
• 61. STEERING WHEEL AND COLUMN ASSEMBLY
• 62. TYPE A STEERING COLUMN ASSEMBLY
• 63. Removal And Disassembly
• 64. Assembly And Installation
• 65. TYPE A STEERING COLUMN
• 66. TYPE A STEERING COLUMN
• 67. TYPE B STEERING COLUMN
• 68. Removal And Disassembly
• 69. Assembly And Installation
• 70. TYPE B STEERING COLUMN
• 71. Disassembly of Steering Control Unit
• 72. Cleaning of Steering Control Unit
• 73. Assembly of Steering Control Unit
• 74. CHECKS AND ADJUSTMENTS
• 75. REMOVE AIR FROM THE SYSTEM
• 76. TROUBLESHOOTING
• 77. INTRODUCTION
• 78. GENERAL
• 79. DESCRIPTION
• 80. REPAIRS
• 81. REMOVAL AND DISASSEMBLY
• 82. CLEANING
• 83. ASSEMBLY
• 84. CHECKS AND ADJUSTMENTS
• 85. INTRODUCTION
• 86. DESCRIPTION
• 87. OPERATION
• 88. Flow Control Valve
• 89. Relief Valve
• 90. REPAIRS
• 91. REMOVAL
• 92. DISASSEMBLY
• 93. CLEANING
• 94. INSPECTION
• 95. ASSEMBLY
• 96. INSTALLATION
• 97. CHECKS AND ADUSTMENTS
• 98. CHECK THE OUTPUT OF THE PUMP
• 99. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
• 100. TROUBLESHOOTING
• 101. INTRODUCTION
• 102. GENERAL
• 103. DESCRIPTION
• 104. OPERATION
• 105. Relief Valve
• 106. REPAIRS
• 107. REMOVAL
• 108. DISASSEMBLY
• 109. ASSEMBLY
• 110. INSTALLATION
• 111. CHECKS AND ADJUSTMENTS
• 112. CHECKING THE RELIEF PRESSURE OF THE RELIEF VALVE
• 113. Lift Trucks With Internal Combustion Engines
• 114. Electric Lift Trucks
• 115. Electric Lift Trucks With Adjustable Relief Valve
• 116. SPECIFICATIONS
• 117. TROUBLESHOOTING
• 118. DC Motor Maintenance
• 119. Safety Precautions Maintenance and Repair
• 120. General
• 121. Brush and Commutator Inspection
• 122. Hydraulic Pump Motor and Traction Motor
• 123. Steering Pump Motor
• 124. Normal Commutator Surface
• 125. Commutator Problems
• 126. Brush Replacement
• 127. Stoning the Commutator
• 128. Motors Repair
• 129. Disassemble
• 130. Traction Motor and Hydraulic Pump Motor
• 131. Steering Pump Motor
• 132. Assemble
• 133. Traction Motor and Hydraulic Pump Motor
• 134. Steering Pump Motor
• 135. Brush Alignment, Traction and Hydraulic Motors
• 136. Tests for Damaged Field and Armature
• 137. Test for an Open Circuit in Armature
• 138. Test for Short Circuit in One Armature Winding
• 139. Test for Short Circuit to Armature Shaft
• 140. Test for Open Circuit in Field Coil
• 141. Test for Short Circuit in Field Coil
• 142. Test for Short Circuit between Field and Motor Case
• 143. Brush Holder Test
• 144. Troubleshooting
• 145. Table 1. Normal Commutator Surfaces
• 146. Table 2. Commutator Problems
• 147. Table 3. Brush Wear Replacement Guide
• 148.
• 148.1. INTRODUCTION
• 148.1.1. General
• 148.1.2. Description
• 148.2. REPAIRS
• 148.2.1. Removal Of The Drive Axle (E20-30BS)
• 148.2.2. Installation
• 148.2.3. Removal Of The Drive Axle (E20-30BH)
• 148.2.4. Installation
• 148.2.5. Wheels And Tires
• 148.2.6. Removal Of The Speed Reducer And Differential
• 148.2.7. Disassembly
• 148.2.8. Assembly
• 148.2.9. Installation Of The Drive Assembly
• 148.3. TROUBLESHOOTING
• 149.
• 149.1. MANUAL STEERING SYSTEM (E20-30BS)
• 149.1.1. System Description
• 149.1.2. Steering Wheel Assembly
• 149.1.3. Steering Column Assembly
• 149.1.4. Steering Gear Assembly
• 149.1.5. Tie Rods And Drag Link
• 149.1.6. Steering Axle Assembly
• 149.1.7. Wheel Hubs And Spindles
• 149.2. POWER STEERING SYSTEM
• 149.2.1. System Description
• 149.2.2. Steering Wheel And Column Assembly
• 149.2.3. Steering Control Unit
• 149.2.4. Power Steering Motor And Pump
• 149.2.5. Power Steering Axle Assembly
• 149.2.6. Steering Cylinder
• 149.2.7. Wheel Hubs And Spindles
• 149.2.8. Inspection Requirements
• 149.2.9. Manual Steering Checks And Adjustments
• 149.3. E20-30BH STEERING SYSTEM SUPPLEMENT
• 149.4. MANUAL STEERING SYSTEM
• 149.4.1. Steering Axle Assembly
• 149.4.2. Wheel Hubs And Spindles
• 149.4.3. Steer Wheel And Tire
• 149.5. POWER STEERING SYSTEM
• 149.5.1. Power Steering Assembly
• 149.5.2. Steering Cylinder
• 149.5.3. Wheel Hubs And Spindles
• 149.5.4. Checks And Adjustments
• 150.
• 150.1. INTRODUCTION
• 150.1.1. General
• 150.1.2. Description
• 150.2. REPAIRS
• 150.2.1. Parking Brake Assembly
• 150.3. ADJUSTMENTS
• 150.3.1. Adjustment of the Hand Brake Linkage
• 150.3.2. Adjustment of the Linkage for the Hand and Seat Brake
• 151.
• 151.1. INTRODUCTION
• 151.1.1. General
• 151.1.2. Description And Operation
• 151.2. REPAIRS
• 151.2.1. Removal And Disassembly
• 151.3. CHECKS AND ADJUSTMENTS
• 151.3.1. Adjustments
• 151.4. TROUBLESHOOTING
• 152.
• 152.1. INTRODUCTION
• 152.1.1. General
• 152.1.2. Description
• 152.1.3. The Control Valve
• 152.2. REPAIRS
• 152.2.1. Hydraulic Pump
• 152.2.2. Main Control Valve
• 152.2.3. Hydraulic Pump Contactor
• 152.2.4. Contactor Repair
• 152.3. CHECKS AND ADJUSTMENTS
• 152.3.1. Adjusting The Pressure Relief Valve
• 152.3.2. Adjustment Of The Control Linkage
• 152.3.3. Hydraulic Pump Switch
• 152.4. TROUBLESHOOTING
• 153.
• 154.
• 154.1. INTRODUCTION
• 154.1.1. GENERAL
• 154.2. PRINCIPLES OF OPERATION
• 154.2.1. LIFT TRUCK CONTROL
• 154.2.2. ELECTRONIC SPEED CONTROLS
• 154.2.3. THE CONTROL CARD FOR THE TRACTION CIRCUIT
• 154.2.4. THERMAL PROTECTION
• 154.2.5. THE 1A CIRCUIT
• 154.2.6. FIELD WEAKENING
• 154.2.7. RAMP START
• 154.2.8. ACCELERATOR CONTROL
• 154.2.9. CONTACTORS AND ELECTRONIC DRIVERS
• 154.2.10. CIRCUIT PROTECTION
• 154.2.11. SEQUENCE OF OPERATION
• 155.
• 155.1. INTRODUCTION
• 155.1.1. GENERAL
• 155.2. DESCRIPTION
• 155.2.1. GENERAL
• 155.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
• 155.2.3. LED DISPLAY PANEL
• 155.2.4. LX SERIES DISPLAY PANEL
• 155.2.5. ZX SERIES DISPLAY PANELS
• 155.3. CHECKS AND ADJUSTMENTS
• 155.3.1. GENERAL
• 155.4. REPLACEMENT
• 155.4.1. GENERAL
• 155.4.2. METER REPLACEMENT
• 155.4.3. SENDER REPLACEMENT
• 155.4.4. DISPLAY PANEL
• 155.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
• 155.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
• 155.5. SPECIFICATIONS
• 155.6. TROUBLESHOOTING
• 156.
• 156.1. ELECTRICAL WARNING DEVICES
• 156.1.1. GENERAL
• 156.1.2. DESCRIPTION
• 156.1.3. REPLACEMENT
• 157.
• 157.1. INTRODUCTION
• 157.1.1. GENERAL
• 157.2. SRO CIRCUIT AND PMT CIRCUIT
• 157.2.1. STATIC RETURN TO OFF(SRO) CIRCUIT
• 157.2.2. PULSE MONITOR TRIP (PMT)
• 157.2.3. THE SEQUENCE OF OPERATION
• 157.3. TROUBLESHOOTING
• 157.3.1. GENERAL PROCEDURES
• 157.4. CHECKS AND REPAIRS
• 157.4.1. GENERAL
• 157.4.2. CHECK FOR THE CORRECT OPERATION
• 157.4.3. CONTROL AND POWER FUSES
• 157.4.4. CONTROL CARD
• 157.4.5. THE INDUCTOR AND CAPACITOR ASSEMBLY (THE OFF CIRCUIT FOR SCR 1)
• 157.4.6. MOTOR CURRENT SENSOR
• 157.4.7. THE ELECTRONIC DRIVER MODULE
• 157.4.8. CONTACTORS
• 157.4.9. CONTACTOR REPAIR
• 157.4.10. CHECK THE PMT CIRCUIT
• 158.
• 159.
• 159.1. INTRODUCTION
• 159.1.1. GENERAL
• 159.1.2. INDICATORS WITH METER MOVEMENT
• 159.1.3. BATTERY INDICATORS WITH LCD OR LED DISPLAYS
• 159.2. CHECKS AND ADJUSTMENTS
• 159.2.1. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS
• 159.2.2. BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS
• 159.2.3. BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS
• 159.2.4. BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS
• 159.2.5. LED DISPLAY WITH LIFT INTERRUPT
• 159.2.6. CHECKING CURTIS 933-1 METER
• 159.2.7. ADJUSTMENT OF CURTIS 933-1 METER
• 159.2.8. ADJUSTMENT OF SEVCON POWERGAUGE
• 159.3. CURTIS DASH DISPLAY ASSEMBLY
• 159.3.1. Description/Features
• 159.3.2. Operation
• 159.3.3. Testing
• 159.4. REPAIRS
• 159.4.1. BATTERY INDICATORS
• 159.4.2. CONTROLLER FOR THE BATTERY INDICATOR
• 159.4.3. DISPLAY PANEL COMPONENTS
• 159.4.4. REPLACING SEM DISPLAY PANEL
• 159.4.5. SEM DISPLAY PANEL REMOVAL
• 160.
• 161.
• 161.1. INTRODUCTION
• 161.1.1. GENERAL
• 161.1.2. STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)
• 161.1.3. FULL FREE-LIFT MASTS
• 161.1.4. THREE-STAGE MASTS
• 161.1.5. FOUR-STAGE MASTS
• 161.1.6. SEQUENCE VALVE
• 162.
• 162.1. INTRODUCTION
• 162.2. REPAIRS
• 162.2.1. Carriage
• 162.2.2. Uprights
• 162.3. CHECKS AND ADJUSTMENTS
• 162.3.1. Checking For Leaks In The Lift System
• 162.3.2. Adjusting The Tilt Cylinder Stroke And Backward Tilt Angle
• 162.3.3. Upright Adjustments
• 162.4. TROUBLESHOOTING
• 163.
• 163.1. INTRODUCTION
• 163.1.1. General
• 163.1.2. Moving A Disabled Lift Truck
• 163.2. MAINTENANCE SCHEDULE
• 163.3. MAINTENANCE PROCEDURES
• 163.3.1. Every 8 Hours or Daily
• 163.3.2. Every 350 Hours or Two Months
• 163.3.3. Every 2000 Hours or Yearly
• 163.3.4. WHEELS AND TIRES
• 163.3.5. CHANGING THE BATTERY
• 164.
• 165.
• 165.1. ELECTRICAL SYSTEM CABLING DIAGRAM
• 165.2. ELECTRICAL SYSTEM SCHEMATIC DIAGRAM 36/48 VOLT (EARLY)
• 165.3. ELECTRICAL SYSTEM WIRING DIAGRAM 36/48 VOLT (EARLY)
• 165.4. ELECTRICAL SYSTEM SCHEMATIC DIAGRAM 36/48 VOLT (LATER)
• 165.5. ELECTRICAL SYSTEM WIRING DIAGRAM 36/48 VOLT (LATER)
• 165.6. HYDRAULIC SYSTEM SCHEMATIC
• 166.