Hyster Industrial Battery Maintenance And Repair

Description

• Model List:
  • Industrial Battery

• 1. RM0001-(03-2020)-UK-EN
• 1.1. General
• 1.2. Battery Type
• 1.2.1. Lead-Acid Batteries
• 1.2.2. Lithium-Ion Batteries
• 1.3. Specific Gravity
• 1.4. Chemical Reaction in a Cell
• 1.5. Electrical Terms
• 1.6. Battery Selection
• 1.7. Battery Voltage
• 1.8. Battery as a Counterweight
• 1.9. Battery Ratings
• 1.9.1. Kilowatt-Hours
• 1.10. Battery Maintenance
• 1.10.1. Safety Procedures
• 1.10.2. Maintenance Records
• 1.10.3. New Battery
• 1.10.4. Cleaning Battery
• 1.10.5. Adding Water to Battery
• 1.10.6. Hydrometer
• 1.10.7. Battery Temperature
• 1.10.8. Charging Battery
• 1.10.9. Where to Charge Batteries
• 1.10.10. Battery Connectors
• 1.10.11. Battery Care
• 1.11. Troubleshooting
• 2. RM0231-(10-2020)-UK-EN
• 2.1. General
• 2.1.1. Threaded Fasteners
• 2.1.2. Nomenclature, Threads
• 2.1.3. Strength Identification
• 2.1.4. Cotter (Split) Pins
• 2.1.5. Fastener Torque Tables
• 2.1.6. Conversion Table
• 3. RM1128-(07-2020)-UK-EN
• 3.1. Series Code / Model Designation Reference Table
• 3.2. General
• 3.3. Deutsch Crimping Tool
• 3.3.1. How to Strip a Wire for Use With Deutsch Crimping Tool
• 3.3.2. How to Crimp With the Deutsch Crimping Tool
• 3.3.3. Calibration Test for the Deutsch Crimping Tool
• 3.4. Deutsch Connectors
• 3.4.1. DT, DTM, and DTP Series Connectors
• 3.4.2. HD Series Connectors
• 3.5. Metri-Pack Connectors
• 3.5.1. Remove and Install
• 3.6. Micro-Pack Connectors
• 3.7. Weather-Pack Connectors
• 3.8. AMPSEAL Crimping Tools
• 3.8.1. AMP Hand Crimping Tool With Certi-Crimp
• 3.8.2. How to use AMP Hand Crimping Tool
• 3.8.3. AMP Pro-Crimper II Tool
• 3.8.4. How to Use AMP PRO-CRIMPER II Tool
• 3.9. AMPSEAL Connector Assemblies
• 3.9.1. Description for Plug Connector Assembly
• 3.9.2. Description for Plug Connector and Header Assembly
• 3.10. AMP Superseal 1.5 Crimping Tools
• 3.10.1. Mini Mic Receptacle and Tab Contacts
• 3.10.2. AMP Hand Application Tool
• 3.10.3. How to Use AMP Hand Application Tool
• 3.10.4. AMP Pro-Crimper II Tool
• 3.10.5. How to Use Pro-Crimper II Tool
• 3.11. AMP Superseal 1.5 Connector Assemblies
• 3.11.1. Description
• 3.11.2. Repair and Maintenance
• 3.11.3. Panel Mount Option
• 3.12. AMP Fastin-Faston Hand Tools
• 3.12.1. Description – AMP Double Action Hand Tool
• 3.12.2. Maintenance and Inspection Procedures
• 3.12.3. How to Use AMP Double Action Hand Tool
• 3.12.4. Description – AMP Extraction Tool
• 3.12.5. Maintenance and Inspection
• 3.12.6. How to Use AMP Extraction Tool
• 3.13. AMP Fastin-Faston Receptacles and Housings
• 3.13.1. Description
• 3.14. Wire Repair
• 3.14.1. Wire Splicing Requirements
• 3.14.2. Deutsch Jiffy Splice
• 3.15. Twisted/Shielded Cable and Leads Repair
• 3.16. Special Tools
• 4. RM1335-(07-2020)-UK-EN
• 4.1. General
• 4.1.1. Description
• 4.1.2. Display Panel Menu Access
• 4.2. Menu Flowchart
• 4.2.1. Supervisor Menu Flowchart
• 4.3. Menu Navigation
• 4.4. Icon Glossary
• 4.4.1. Introduction
• 4.4.2. Soft Key Icons
• 4.4.3. Overlay Icons
• 4.4.4. Icons on System Off Screen and Alert Screens
• 4.4.5. Main Menu Title Screens
• 4.4.6. Submenu Icons Grouped by Menu
• 4.5. Operating Screen
• 4.5.1. Introduction
• 4.5.2. Performance Mode Controls
• 4.5.3. Status and Warning Icons
• 4.5.4. Battery Discharge Indicator
• 4.5.5. Direction and Parking Brake Indicators
• 4.5.6. Hazard Flashers and Lighting Controls
• 4.5.7. Steer Angle Indicator
• 4.5.8. System Time
• 4.5.9. Load Weight Indicator
• 4.6. System Off/Alert Screens
• 4.6.1. Introduction
• 4.6.2. System Off Screen
• 4.6.3. Alert Screens
• 4.7. Password Screen
• 4.7.1. Introduction
• 4.7.2. Password Screen
• 4.7.3. Adding/Removing/Changing Passwords
• 4.7.4. Password Log
• 4.8. Activity Log Menu
• 4.8.1. Introduction
• 4.8.2. Operator Checklist Log
• 4.8.3. Password Log
• 4.8.4. Impact Events Log
• 4.9. Calibration Menu
• 4.9.1. Introduction
• 4.9.2. Load Weight Calibration
• 4.9.3. Return to Set Tilt Stop Point Calibration
• 4.9.4. E-Hydraulic and Manual Valve Threshold Calibration
• 4.9.5. Steering Wheel Center Point Calibration
• 4.9.6. Steer Axle Position Calibration
• 4.9.7. Steer Axle Center Point Calibration
• 4.9.8. Manual Hydraulics Calibration
• 4.10. Display Menu
• 4.10.1. Introduction
• 4.10.2. Set Date and Time Format Menu
• 4.10.3. Set Daylight Saving Time Menu
• 4.10.4. Set Time and Date Menu
• 4.10.5. Set Units Menu
• 4.11. Status Menu
• 4.11.1. Introduction
• 4.11.2. VSM Versions
• 4.11.3. Display Versions
• 4.11.4. Truck Serial Number
• 4.11.5. Hour Meters
• 4.11.6. E-Hydraulic Controller Versions
• 4.11.7. Pump Motor Controller Versions
• 4.11.8. Traction Motor Controller 1 Versions
• 4.11.9. Traction Motor Controller 2 Versions
• 4.11.10. Light Controller Versions
• 4.11.11. Impact Sensor Versions
• 4.12. Truck Setup Menu
• 4.12.1. Introduction
• 4.12.2. Add/Remove Password
• 4.12.3. Battery Settings
• 4.12.4. Restore Default Settings
• 4.12.5. Motion Alarm
• 4.12.6. Impact Monitor Settings
• 4.12.7. Auto Power-Off Time Delay
• 4.12.8. Return to Set Tilt
• 4.12.9. Traction Speed Limit
• 4.12.10. Scheduled Maintenance Reminder
• 4.12.11. Minimum Pump Standby Flow Rate
• 4.12.12. Operator Checklist
• 4.12.13. Impact Monitor Shutdown
• 4.12.14. Motor Braking
• 4.12.15. Steering Wheel Friction and Steering Turns Adjustment
• 5. RM1336-(07-2020)-UK-EN
• 5.1. General
• 5.1.1. Description
• 5.1.2. Display Panel Menu Access
• 5.2. Menu Flowchart
• 5.2.1. Technician Menu Flowchart
• 5.3. Menu Navigation
• 5.4. Icon Glossary
• 5.4.1. Introduction
• 5.4.2. Soft Key Icons
• 5.4.3. Overlay Icons
• 5.4.4. Heat Exchange Module Warning Indicator Screen
• 5.4.5. System Off Screen and Alert Screens
• 5.4.6. Main Menu Title Screens
• 5.4.7. Submenu Icons Grouped by Menu
• 5.5. Operating Screen
• 5.5.1. Introduction
• 5.5.2. Performance Mode Controls
• 5.5.3. Status and Warning Icons
• 5.5.4. Battery Discharge Indicator
• 5.5.5. Direction and Parking Brake Indicators
• 5.5.6. Hazard Flashers and Lighting Controls
• 5.5.7. Steer Angle Indicator
• 5.5.8. System Time
• 5.5.9. Load Weight Indicator
• 5.6. System Off/Alert Screens
• 5.6.1. Introduction
• 5.6.2. System Off Screen
• 5.6.3. Alert Screens
• 5.7. Password Screen
• 5.7.1. Introduction
• 5.7.2. Password Screen
• 5.7.3. Adding/Removing/Changing Passwords
• 5.7.4. Password Log
• 5.8. Activity Log Menu
• 5.8.1. Introduction
• 5.8.2. Operator Checklist Log
• 5.8.3. Password Log
• 5.8.4. Impact Events Log
• 5.9. Calibration Menu
• 5.9.1. Introduction
• 5.9.2. Load Weight Calibration
• 5.9.3. Return to Set Tilt Stop Point Calibration
• 5.9.4. E-Hydraulic and Manual Valve Threshold Calibration
• 5.9.5. Steering Wheel Center Point Calibration
• 5.9.6. Steer Axle Position Calibration
• 5.9.7. Steer Axle Center Point Calibration
• 5.9.8. Manual Hydraulics Calibration
• 5.10. Display Menu
• 5.10.1. Introduction
• 5.10.2. Set Date and Time Format Menu
• 5.10.3. Set Daylight Saving Time Menu
• 5.10.4. Set Time and Date Menu
• 5.10.5. Set Units Menu
• 5.11. Status Menu
• 5.11.1. Introduction
• 5.11.2. VSM Versions
• 5.11.3. Display Versions
• 5.11.4. Truck Serial Number
• 5.11.5. Hour Meters
• 5.11.6. E-Hydraulic Controller Versions
• 5.11.7. Pump Motor Controller Versions
• 5.11.8. Traction Motor Controller 1 Versions
• 5.11.9. Traction Motor Controller 2 Versions
• 5.11.10. Light Controller Versions
• 5.11.11. Impact Sensor Versions
• 5.11.12. E-Steer Controller 1 Versions
• 5.11.13. E-Steer Controller 2 Versions
• 5.12. Truck Setup Menu
• 5.12.1. Introduction
• 5.12.2. Add/Remove Password
• 5.12.3. Battery Settings
• 5.12.4. Motor Braking
• 5.12.5. Battery Mode
• 5.12.6. Battery Setup
• 5.12.7. BDI Adjustment Setting
• 5.12.8. Acceleration Rates
• 5.12.9. Hour Meter Initialization
• 5.12.10. Impact Monitor Shutdown
• 5.12.11. Operator Checklist
• 5.12.12. Minimum Pump Standby Flow Rate
• 5.12.13. Scheduled Maintenance Reminder
• 5.12.14. Traction Speed Limit
• 5.12.15. Return to Set Tilt
• 5.12.16. Auto Power-Off Time Delay
• 5.12.17. Impact Monitor Settings
• 5.12.18. Motion Alarm
• 5.12.19. Lift Hydraulic Function Maximum Speed and Ramp Times
• 5.12.20. Lower Hydraulic Function Maximum Speed and Ramp Times
• 5.12.21. Tilt Forward Hydraulic Function Maximum Speed and Ramp Times
• 5.12.22. Tilt Backward Hydraulic Function Maximum Speed and Ramp Times
• 5.12.23. Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times
• 5.12.24. Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times
• 5.12.25. Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times
• 5.12.26. Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times
• 5.12.27. Optional Hydraulic Functions
• 5.12.28. Rear Lights Control
• 5.12.29. Restore Default Settings
• 5.12.30. Steering Wheel Friction and Steering Turns Adjustment
• 5.13. Diagnostics Menu
• 5.13.1. Introduction
• 5.13.2. Fault Code Log
• 5.13.3. Speedometer
• 5.13.4. Direction Switch
• 5.13.5. Traction Motor 1 Status
• 5.13.6. Traction Motor 2 Status
• 5.13.7. Occupancy Sensor
• 5.13.8. Brake System Sensors
• 5.13.9. Pump Status
• 5.13.10. Hydraulic Control Inputs
• 5.13.11. E-Hydraulic Valves
• 5.13.12. Hydraulic Sensors
• 5.13.13. System Voltages
• 5.13.14. Steering Position Sensors
• 5.13.15. E-Steering Position Sensors
• 5.13.16. Electric Brake
• 6. RM1377-(09-2019)-UK-EN
• 6.1. SECTION 9010 Operational Diagnostic Procedures
• 6.1.1. Group 05 – Operational Checkout
• 6.2. SECTION 9025 Traction Motor
• 6.2.1. Group 10 – Principles of Operation
• 6.2.2. Group 30 – Observed Symptoms
• 6.3. SECTION 9030 Electrical System
• 6.3.1. Group 03 – General Maintenance and Diagnostic Data
• 6.3.2. Group 10 – Principles of Operation
• 6.3.3. Group 20 – Diagnostic Trouble Codes
• 6.3.4. Group 30 – Observed Symptoms
• 6.3.5. Group 55 – Icons and Graphics
• 6.4. SECTION 9035 Drive Axle/Unit
• 6.4.1. Group 10 – Principles of Operation
• 6.4.2. Group 30 – Observed Symptoms
• 6.5. SECTION 9050 Hydraulic Systems
• 6.5.1. Group 10 – Principles of Operation
• 6.5.2. Group 33 – Observed Symptoms-Gear Pump
• 6.5.3. Group 43 – Tests and Adjustments-Gear Pump
• 6.6. SECTION 9060 Operators Station
• 6.6.1. Group 10 – Principles of Operation
• 6.7. SECTION 9070 Front End (Mast) and Chassis
• 6.7.1. Group 10 – Principles of Operation
• 6.7.2. Group 30 – Observed Symptoms
• 6.8. SECTION 9080 Supplementary Data
• 6.8.1. Group 50 – Abbreviations and Acronyms
• 7. RM1446-(09-2014)-UK-EN
• 8. RM1514-(12-2013)-UK-EN
• 9. RM1515-(12-2013)-UK-EN
• 10. RM1516-(12-2013)-UK-EN
• 11. RM1517-(12-2013)-UK-EN
• 12. RM1518-(12-2013)-UK-EN
• 13. RM1519-(05-2014)-UK-EN
• 14. RM1520-(05-2014)-UK-EN
• 15. RM1521-(11-2015)-UK-EN
• 15.1. Safety Procedures When Working Near Mast
• 15.2. General
• 15.3. Description
• 15.4. Tilt Cylinder Repair
• 15.4.1. Disassemble
• 15.4.2. Inspect
• 15.4.3. Assemble
• 15.4.4. Install
• 15.4.5. Tilt Cylinders, Adjust
• 15.4.6. Tilt Cylinders Leak Check
• 15.5. Lift Cylinder Repair
• 15.5.1. Main Lift Cylinder (Mast a270, a271 and a272)
• 15.5.2. Main Lift Cylinder (Mast c662)
• 15.6. Free Lift Cylinder Repair
• 15.6.1. Free-Lift Cylinder (Mast a271 and a272)
• 15.6.2. Free-Lift Cylinder (Mast c662)
• 15.7. Sideshift Cylinder Repair
• 15.7.1. Disassemble
• 15.7.2. Clean and Inspect
• 15.7.3. Assemble and Install
• 15.8. Seal Kit Installation
• 15.8.1. External Installation (Seal and Back-Up Ring)
• 15.8.2. Internal Installation (Piston Rod Assembly)
• 15.9. Torque Specifications
• 15.9.1. Tilt Cylinders
• 15.9.2. Main and Free-Lift Cylinders
• 15.9.3. Sideshift Cylinder
• 16. RM1524-(01-2020)-UK-EN
• 16.1. General
• 16.1.1. Discharging the Capacitors
• 16.2. Display Panel and Key or Keyless Switch Replacement
• 16.2.1. Display Panel, Replace
• 16.3. Electronic and Manual Hydraulic Controls
• 16.3.1. General
• 16.3.2. Manual Hydraulic Controls
• 16.3.3. E-Hydraulic Controls – Test
• 16.3.4. E-Hydraulic Controls
• 16.4. Electronic-Hydraulic Controls, After January, 2020
• 16.4.1. General
• 16.4.2. E-Hydraulic Controls – TEST
• 16.4.3. Mini-levers, Remove and Install
• 16.4.4. Armrest Assembly
• 16.4.5. Horn Button
• 16.4.6. Direction Control Switch
• 16.4.7. Emergency Disconnect Switch
• 16.4.8. push (override) button
• 16.5. Sensors and Switches
• 16.5.1. General
• 16.5.2. Hydraulic Motor Speed Sensor
• 16.5.3. Hydraulic Motor Temperature Sensor
• 16.5.4. Traction Motor Temperature Sensor
• 16.5.5. Traction Motor Speed Sensor
• 16.5.6. Low Level Brake Fluid Switch
• 16.5.7. Service Brake Pressure Sensor
• 16.5.8. Accelerator Pedal Position Sensor