Hyster B435 (R1.4, R1.6, R1.8, R2.0) Forklift Service Repair Manual

Hyster B435 (R1.4, R1.6, R1.8, R2.0) Forklift

Part No: 2794340

Technical Information for HYSTER Service Centres

This manual is designated solely for the skilled technicians of the HYSTER service network

R 1.4 / 1.6 / 1.8 / 2.0

SERVICE

Section: ELECTRICAL CONTENTS SYSTEM Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0

ELECTRIC

GENERAL SAFETY RULES NEVER DO ANY CLEANING, LUBRICATING OR SERVICING WITH THE BATTERY CONNECTED. DO NOT WEAR ANY RINGS, WATCHES, JEWELLERY, ITEMS OF CLOTHING THAT ARE LOOSE OR HANG DOWN, SUCH AS SCARVES, UNBUTTONED OR UNZIPPED JACKETS OR SHIRTS THAT COULD GET CAUGHT UP IN MOVING PARTS. WHILE IT IS RECOMMENDED TO WEAR ITEMS OF APPAREL WITH ACCIDENT-PREVENTION APPROVAL, SUCH AS: HELMETS, NONSLIP FOOTWEAR, GLOVES, SAFETY GOGGLES. NEVER USE PETROL, DIESEL OR OTHER FLAMMABLE LIQUIDS AS DETERGENTS: USE INSTEAD NON-FLAMMABLE, NONTOXIC TRADE SOLVENTS. DO NOT SMOKE, USE NO NAKED FLAMES NOR CAUSE ANY SPARKS NEARBY WHEN HANDLING EASILY FLAMMABLE MATERIALS. n n n n n n n n n n n

If working outside the workshop, set the machine preferably on the level and lock it. If working on a slope is inevitable, lock the machine beforehand and move it to a level area as soon as this is possible with a certain safety margin.

Disconnect the batteries and label all the controls to warn of the work in progress. Lock the machine and all equipment that has to be lifted.

When towing, use solely the prescribed points of connection and make sure the pins and/or bolts are firmly secured before starting to pull. Lift and handle all heavy parts with lifting equipment of suitable capacity. Use the specific lifting eyes. Be careful of people close to the load to lift.

Do not get chains or metal ropes tangled up.

Do not trust bent or damaged chains and ropes: do not use them for lifting or pulling. Always wear safety gloves when handling them.

Handle all parts carefully, do not put your hands or fingers between one part and another.

Wear the type-approved accident-prevention equipment such as safety goggles, gloves and footwear.

The area where maintenance work is performed must be kept clean and dry. Immediately remove any puddles of water or oil stains.

Do not pile up rags soaked in grease or oil: they are a serious fire hazard. Always put them away in a closed metal container.

Do not do any servicing on the machine with people at the controls, unless they are accredited operators helping in the work to be done.

When using compressed air to clean parts, protect yourself with goggles that have side guards.

Welding n When welding is required, you must use the envisaged means of accident prevention: dark goggles, helmet, overalls, gloves, footwear. Dark goggles should also be worn by anyone not doing the welding but are nearby. Never look at the welding arc without appropriately protecting your eyes.

Batteries n When using batteries, remember that the cables must be connected at both ends to the terminals as required: (+) with (+) and (-) with (-). n Do not short the terminals.

The gas given off when recharging is highly flammable. When recharging, leave the battery bay open for more effective ventilation and take off the caps.

ADMIT NO SPARKS OR FLAMES IN THE BATTERY AREA! n n n

Never check the battery charge with ”bridges” of metal objects spanning the terminals.

Before doing any work, check no elements are short-circuiting.

Always disconnect the batteries before doing any work on the electric system.

For battery chargers and similar equipment, use only auxiliary power supplies with effective earth connections in order to avoid possible electric shock.

Hydraulic system n Fluid blowing through a tiny hole may be virtually invisible yet be strong enough to penetrate under your skin; in these cases, having to check, use a piece of card or wood. Never do it with your hands.

Having to check the pressure in the system, use the appropriate instruments.

NOTE: THIS MANUAL IS NO SUBSTITUTE FOR THE OPERATING AND MAINTENANCE MANUAL, BUT A SUPPLEMENT TO IT

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SERVICE SERVICE

Section: ELECTRICAL CONTENTS SYSTEM

R 1.4 1.4 // 1.6 1.6 // 1.8 1.8 // 2.0 2.0 R

CONTENTS Section: ELECTRICAL SYSTEM 1. 0 1. 1 1. 2 1. 3 1. 4 1. 5 1. 6 1. 7 1. 8 1. 9 1. 10 1. 11 1. 12 1. 13 1. 14 1. 15 1. 16 1. 17 1. 18 1. 19 1. 20 1. 21 1. 22 2. 0 2. 1 2. 2 2. 3 2. 4 2. 5 2. 6 2. 7 2. 8 2. 9 2. 10 3. 0 3. 1 3. 2 3. 3 3. 4 3. 5 3. 6 3. 7 3. 8 3. 9 3. 10 3. 11 4. 0 4. 1 4. 2

WIRING DIAGRAM LEGEND R 1.4/1.6/1.8/2.0 ....................................................................................................................... 8 DRIVE/LIFTING ELECTRONIC PANEL COMPONENTS ...................................................................................................... 12 ELECTRIC STEERING SYSTEM .......................................................................................................................................... 14 ELECTRONIC CONTROL DRIVE MOTOR CHOPPER SEM2 ............................................................................................. 15 GUARDS ............................................................................................................................................................................... 17 SEM2 CHOPPER FAULT DIAGNOSIS ................................................................................................................................. 18 PRINCIPLE OF OPERATION OF SEM2 CONTROL ............................................................................................................. 19 DEFINITION OF DIRECTION OF TRAVEL OF MACHINE .................................................................................................... 20 SEM2 CHOPPER MECHANICAL DRAWING ...................................................................................................................... 21 PROGRAMMING CONSOLE ................................................................................................................................................ 22 CONNECTORS ..................................................................................................................................................................... 25 MENU / SET OPTIONS CONFIGURATION .......................................................................................................................... 28 SYSTEM CONFIGURATION TABLES .................................................................................................................................. 30 MENU / PARAMETER CHANGE CONFIGURATION ........................................................................................................... 31 SETTINGS TABLE ................................................................................................................................................................ 33 MAIN MENU / TESTER ......................................................................................................................................................... 35 MAIN MENU / SAVE PARAMETER ...................................................................................................................................... 38 MAIN MENU / RESTORE PARAMETER .............................................................................................................................. 39 MAIN MENU / ALARMS ........................................................................................................................................................ 40 MAIN MENU / PROGRAM VACC ......................................................................................................................................... 41 DRIVE SEM2 CHOPPER SETTING SEQUENCES .............................................................................................................. 42 SEM2: TROUBLESHOOTING ............................................................................................................................................... 43 NEGATIVE BRAKE CONTROL ............................................................................................................................................. 46 ELECTRONIC CONTROL PUMP MOTOR CHOPPER HPRC ............................................................................................. 52 POWER CONNECTIONS ..................................................................................................................................................... 53 SIGNAL CONNECTIONS ...................................................................................................................................................... 53 CONNECTORS ..................................................................................................................................................................... 54 PROGRAMMING CONSOLE ................................................................................................................................................ 56 PRELIMINARY CHECKS ...................................................................................................................................................... 59 PROGRAMMING ................................................................................................................................................................... 60 MENU / PARAMETER CHANGE CONFIGURATION ........................................................................................................... 61 MAIN MENU / TESTER ......................................................................................................................................................... 66 MAIN MENU / ALARMS ........................................................................................................................................................ 69 HPRC: TROUBLESHOOTING .............................................................................................................................................. 70 ELECTRIC STEERING EPS-DC BOARD ............................................................................................................................. 73 CONTROL UNIT ................................................................................................................................................................... 74 LOGIC BOARD ...................................................................................................................................................................... 74 CONNECTING DIAGRAM .................................................................................................................................................... 75 PROGRAMMING CONSOLE ................................................................................................................................................ 76 STEERING WITH TACHOMETRIC DYNAMO ...................................................................................................................... 79 DESCRIPTION OF ALARMS ................................................................................................................................................ 80 LIST OF PARAMETERS OF MAIN MENU ............................................................................................................................ 83 MAIN MENU: ALARMS FUNCTION ..................................................................................................................................... 84 MENU /SET OPTIONS CONFIGURATION ........................................................................................................................... 85 MENU / ADJUSTMENTS CONFIGURATION ....................................................................................................................... 87 SAFETY PERFORMANCE: OPERATING PROVISIONS AND DESCRIPTION ................................................................... 89 DISPLAY INSTRUMENT ....................................................................................................................................................... 92 DESCRIPTION OF DISPLAY ................................................................................................................................................ 93 REMOVING THROTTLE PEDAL BOARD ............................................................................................................................ 94

CONTENTS Section: HYDRAULIC SYSTEM 1. 0 1. 1 1. 2 1. 3 1. 4 1. 5 1. 6 1. 7

HYDRAULIC SYSTEM SYMBOL LEGEND R 1.4/1.6/1.8/2.0 .................................................................................................. 3 TABLE OF HYDRAULIC SYSTEM COMPONENTS ................................................................................................................. 4 SOLENOID VALVE HYDRAULIC ASSEMBLY .......................................................................................................................... 7 TABLE OF SOLENOID VALVE HYDRAULIC ASSEMBLY ....................................................................................................... 8 CARRIAGE SIDE-SHIFT CYLINDER COMPONENTS ........................................................................................................... 8 TABLE OF CARRIAGE SIDE-SHIFT CYLINDER COMPONENTS ......................................................................................... 9 TRAINING CYLINDER COMPONENTS ............................................................................................................................... 10 TABLE OF TRAINING CYLINDER COMPONENTS ............................................................................................................. 10

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ELECTRIC

TruckModel Model//Carrello CarrelloTipo Tipo//Chariot ChariotModele Modele//Staplertyp Staplertyp//Tipo Tipode decarretilla carretilla Truck

SERVICE

Section: ELECTRICAL CONTENTS SYSTEM

ELECTRIC

Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

2. 0 3. 0 3. 1 4. 0 5. 0 5. 1 6. 0 7. 0 8. 0 8. 1 8. 2 8. 3 8. 4 9. 0 9. 1 10. 0 10. 1 10. 2

R 1.4 / 1.6 / 1.8 / 2.0

REMOVING CARRIAGE SIDE-SHIFT CYLINDER ............................................................................................................... 11 REMOVING TRAINING CYLINDER ..................................................................................................................................... 13 REPLACING GASKETS ........................................................................................................................................................ 15 REPLACING FORK TRAVERSING CYLINDER GASKETS ................................................................................................. 16 REMOVING SOLENOID VALVE ASSEMBLY ...................................................................................................................... 19 CLEANING SOLENOID VALVE ASSEMBLY INLET FILTERS ............................................................................................. 21 SETTING HYDRAULIC PRESSURE .................................................................................................................................... 22 REMOVING TWIN PIPES ...................................................................................................................................................... 24 LIFTING CYLINDERS ........................................................................................................................................................... 27 LIFTING CYLINDER POSITION ............................................................................................................................................ 27 CENTRAL HYDRAULIC LIFTING CYLINDER ..................................................................................................................... 28 REPLACING CYLINDER ROD ............................................................................................................................................. 29 COMPLETE REPLACEMENT OF CENTRAL HYDRAULIC CYLINDER ............................................................................. 29 SIDE HYDRAULIC LIFTING CYLINDERS ............................................................................................................................ 29 REPLACING GASKETS ........................................................................................................................................................ 29 SIDE LIFTING SINGLE-ACTING HYDRAULIC CYLINDERS ............................................................................................... 30 REMOVING THE SIDE CYLINDERS .................................................................................................................................... 30 REPLACING THE GASKETS ................................................................................................................................................ 53

CONTENTS Section: MECHANICS 1. 0 1. 1 2. 0 3. 0 4. 0 5. 0 6. 0 7. 0 8. 0 9. 0 10. 0

COMPONENTS OF FORK PLATE COMPLETE WITH FORK SIDE-SHIFT R 1.4/1.6/1.8/2.0 ................................................. 2 TABLE OF COMPONENTS OF FORK PLATE COMPLETE WITH FORK SIDE-SHIFT ............................................................ 3 REMOVING FRONT LOADING WHEELS ............................................................................................................................... 4 REMOVING DRIVING WHEEL ............................................................................................................................................... 6 REMOVING DRIVING MOTOR ............................................................................................................................................... 8 REMOVING MOTOR PUMP ................................................................................................................................................. 12 REMOVING DRIVER’S SEAT CASING ................................................................................................................................ 15 REMOVING STEERING GEAR MOTOR ............................................................................................................................... 16 REMOVING STEERING GEAR CHAIN ................................................................................................................................ 19 REPLACING FORK TRAVERSE SLIDING BLOCKS ........................................................................................................... 20 REMOVING TRAVERSE CARRIAGE ................................................................................................................................... 22

CONTENTS Section: MASTS 1. 0 2. 0 3. 0 3. 1 3. 2 3. 3 3. 4 3. 5 4. 0 5. 0 6. 0 7. 0 7. 1 7. 2 7. 3 7. 4 7. 5 8. 0 8. 1 8. 2 9. 0 9. 1 9. 2 9. 3 9. 4

TYPE OF MASTS ..................................................................................................................................................................... 2 LOCATION OF MAIN TRUCK COMPONENTS ........................................................................................................................ 3 COMPLETE MAST ASSEMBLY PROCEDURE ..................................................................................................................... 4 LIFTING THE MAST ................................................................................................................................................................ 4 LOCKING THE MAST ON THE TRAVERSE CARRIAGE ....................................................................................................... 4 CONNECTING HYDRAULIC PIPES ....................................................................................................................................... 5 CONNECTING BREATHER PIPE .......................................................................................................................................... 6 LOCKING FINAL MAST .......................................................................................................................................................... 6 BLEEDING THE HYDRAULIC CIRCUIT ................................................................................................................................ 7 FITTING LIFTING FORKS ....................................................................................................................................................... 8 REMOVING MAST .................................................................................................................................................................. 9 DESCRIPTION OF BEARINGS ............................................................................................................................................. 10 BEARINGS ............................................................................................................................................................................ 10 GREASING THE BEARINGS ................................................................................................................................................ 10 REPLACING THE BEARINGS .............................................................................................................................................. 11 CLEARANCE BETWEEN BEARING AND PROFILE ........................................................................................................... 11 MAIN CAUSES OF BEARINGS BREAKING ......................................................................................................................... 12 RACES .................................................................................................................................................................................. 12 GREASING THE RACES ...................................................................................................................................................... 12 WEAR OF RACES ................................................................................................................................................................ 12 CHAINS ................................................................................................................................................................................. 13 GREASING CHAINS ............................................................................................................................................................. 13 WEAR OF CHAINS ............................................................................................................................................................... 13 ADJUSTING THE CHAIN ...................................................................................................................................................... 13 REPLACING THE CHAIN ..................................................................................................................................................... 14

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SERVICE SERVICE

Section: ELECTRICAL CONTENTS SYSTEM

R 1.4 1.4 // 1.6 1.6 // 1.8 1.8 // 2.0 2.0 R

CONTENTS Section: REDUCTION GEAR 1. 0 1. 1 1. 2 2. 0 3. 0 4. 0

REDUCTION GEAR COMPONENTS R 1.4/1.6/1.8/2.0 .......................................................................................................... 2 TABLE OF COMPONENTS OF REDUCTION GEAR ............................................................................................................... 3 SPECIAL TOOLS FOR FITTING COMPONENTS ................................................................................................................... 4 REMOVING THE REDUCTION GEAR .................................................................................................................................... 8 DISMANTLING THE REDUCTION GEAR ............................................................................................................................ 14 ASSEMBLING THE REDUCTION GEAR COMPONENTS ..................................................................................................... 8

CONTENTS Section: BRAKING SYSTEM 1. 0 1. 1 1. 2 1. 3 1. 4 2. 0 3. 0 4. 0

BRAKING SYSTEM COMPONENTS R 1.4/1.6 ........................................................................................................................ 2 BRAKING SYSTEM COMPONENTS R 1.8/2.0 ........................................................................................................................ 3 TABLE OF BRAKING SYSTEM COMPONENTS ...................................................................................................................... 4 NEGATIVE BRAKE COMPONENTS ........................................................................................................................................ 5 TABLE OF NEGATIVE BRAKE COMPONENTS ....................................................................................................................... 6 BRAKING SYSTEMS ............................................................................................................................................................... 7 REMOVING THE BRAKE PUMP ............................................................................................................................................ 8 REMOVING THE PASSIVE BRAKE CYLINDER/REMOVING THE SERVICE BRAKE CYLINDER .................................... 11

CONTENTS Section: ACCESSORIES ON REQUEST

1. 0 1. 1 1. 2 2. 0 2. 1 2. 2 3. 0 3. 1 3. 2 4. 0 4. 1 4. 2 4. 3 5. 0 5. 1 5. 2 5. 3 5. 4 6. 0 6. 1 6. 2 7. 0 7. 1 7. 2 8. 0 8. 1 8. 2 9. 0 9. 1 9. 2

STEERING GEAR POSITION INDICATOR .............................................................................................................................. 4 FITTING THE WHEEL POSITION INDICATOR ....................................................................................................................... 5 TABLE OF WHEEL POSITION INDICATOR ............................................................................................................................ 6 APPLICATION 5TH LEVER FOR ADDITIONAL EQUIPMENT ................................................................................................... 8 ASSEMBLY 5TH LEVER (AUXILIARY FUNCTIONS) ................................................................................................................. 9 TABLE ASSEMBLY 5TH LEVER (AUXILIARY FUNCTIONS) ................................................................................................... 10 FITTING THE PARKING BRAKE ........................................................................................................................................... 12 COMPLETE KIT FOR FITTING PARKING BRAKE ............................................................................................................... 13 TABLE FOR FITTING PARKING BRAKE .............................................................................................................................. 14 FITTING REVOLVING LIGHT AND REVERSING AUDIBLE WARNING .............................................................................. 16 FITTING REVERSING AUDIBLE WARNING ........................................................................................................................ 17 FITTING REVOLVING LIGHT OR LAMPALLARM ................................................................................................................ 18 TABLE FOR FITTING REVOLVING LIGHT OR LAMPALLARM ........................................................................................... 19 FITTING LOW GEAR SELECTORS ...................................................................................................................................... 22 FITTING LOW GEAR SWITCH .............................................................................................................................................. 23 TABLE FOR FITTING LOW GEAR SWITCH ......................................................................................................................... 23 FITTING LOW GEAR PUSH-BUTTON WITH BATTERY OUT .............................................................................................. 24 TABLE FOR FITTING LOW GEAR PUSH-BUTTON WITH BATTERY OUT ......................................................................... 24 FITTING WORKING LIGHTS ................................................................................................................................................. 26 FITTING WORKING LIGHT ASSEMBLY ............................................................................................................................... 27 TABLE FOR FITTING WORKING LIGHTS ............................................................................................................................ 28 TRANSFORMATION KIT -30°C ............................................................................................................................................ 30 COLD STORAGE VERSION ................................................................................................................................................. 31 TABLE OF COLD STORAGE VERSION ............................................................................................................................... 33 FITTING HEIGHT DISPLAY .................................................................................................................................................. 36 HEIGHT INDICATOR ASSEMBLY ........................................................................................................................................ 37 TABLE OF HEIGHT INDICATOR ASSEMBLY ...................................................................................................................... 38 FITTING VIDEO CAMERA ASSEMBLY ................................................................................................................................ 40 VIDEO CAMERA ASSEMBLY .............................................................................................................................................. 41 TABLE OF VIDEO CAMERA ASSEMBLY ............................................................................................................................ 42

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ELECTRIC

TruckModel Model//Carrello CarrelloTipo Tipo//Chariot ChariotModele Modele//Staplertyp Staplertyp//Tipo Tipode decarretilla carretilla Truck

SERVICE

Section: ELECTRICAL CONTENTS SYSTEM Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0

ELECTRIC

NOTES:

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SERVICE

Section: ELECTRICAL SYSTEM

R 1.4 / 1.6 / 1.8 / 2.0 ELECTRIC ELECTRIC

Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

ELECTRIC SYSTEM å

WIRING DIAGRAMS ...................................................................................................... page 9

å

ELECTRIC PANEL COMPONENTS ............................................................................. page 12

å

ELECTRIC STEERING SYSTEM .................................................................................. page 14

å

ELECTRONIC CONTROL DRIVE MOTOR CHOPPER SEM2 ..................................... page 15

å

ELECTRONIC CONTROL PUMP MOTOR CHOPPER HPRC ..................................... page 52

å

ELECTRIC STEERING EPS-DC BOARD ..................................................................... page 73

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SERVICE

Section: ELECTRICAL SYSTEM

ELECTRIC

Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0

1.0 WIRING DIAGRAM LEGEND MOD. R 1.4/1.6/1.8/2.0 Ref. 1

cable no.1

2

cable no.2

3

cable no.3

4

cable no.4

5

cable no.5

BAT TG. CONTACTOR FU2

power fuse 300A

FU3

power fuse 300A

MTR

drive motor

M1

cable no.11 drive motor armature cable M1

M2

cable M2

FLD

drive motor field

M3

cable M3

M4

cable M4

6

cable M6

7

cable M7

MS

steering motor servo

MS1

cable MS1

MS2

cable MS2

10

cable no.10

11

cable no.11

ARM

motor pump armature

FLD

motor pump field

FW

field weakening contact

MP

pump motor

P-

cable P-

P+

cable P+

8

cable no.8

PB

cable PB

TB. CONTACTOR

lifting BY-PASS contactor

FU4

auxiliary fuse 5A

FU5

auxiliary fuse 3A

FU6

auxiliary fuse 3A

FU7

auxiliary fuse 5A

FU8

auxiliary fuse 7A

FU9

auxiliary fuse 7A

SW9 D1 MOV1

ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü

key contactor power fuse 35A

ARM

R 1.4/1.6/1.8/2.0

battery

FU1

11

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Component description

emergency push-button contact NO diode 1N4004 arcing contact MOV. 50 Vac d=10 mm

R11

resistance 10oh-1w 5%

RL1

feme relay 16A 48V

SW1

key contact NO

CPS

electronic control of electric guide

CS1

electric guide control connector

FA

electric guide control fan 48v

C3

capacitor 47uf 100V el.vert.

DT

tachometric dynamo

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SERVICE

Section: ELECTRICAL SYSTEM

Ref.

Component description

PTC

PTC (temperature switch)

C4

capacitor 47uf 63V el.vert.

DZ3

diode zener 24V 5W

DZ4

diode zener 24V 5W

R12

resistor 4.7-ohm 2W

J2

jumper 3pin

LS1

right steering limit stop sensor

LS2

left steering limit stop sensor

R5

resistor 1.8Kohm 2w 5%

R6

resistor 1.8Kohm 2w 5%

CA1

alarm buzzer 12V electric guide

L1

diode LED alarm electric guide

J3

jumper 3pin

PRESS

negtive brake pressure switch NC

LS3

travelling lift truck speed reduction sensor

LD1

green LED diode

LS4

lifting speed reduction sensor

EV7

negative brake solenoid valve

LS5

lowering speed reduction sensor

LS6

sensor to be defined

LS7

battery out sensor

batt. Out

battery out

Rsens

lifting logic temperature switch

J4

jumper 3 pin

Batt. Flat

flat battery NC contact

ACC1

drive control pedal board

TB

BY contactor coil

EV1

forward truck solenoid valve coil

SW2

N/O pedal board start microswitch

EV2

backward truck solenoid valve coil

PSPB

pedal brake pressure switch

J5

jumper 3 pin

SW3

dead-man microswitch

SW4

horn control button

J1

jumper 3 pin

TG

main contactor coil

EV5

backward travelling lift solenoid valve coil

HO

horn

C2

capacitor 100uf 100V el.vert.

R3

resistor 18-Ohm 1W 5%

RWD

reverse gear indicator LED diode

SW5

N/O reverse gear microswitch

SW6

N/O forward gear microswitch

EV6

forward travelling lift solenoid valve coil

EV9

lifting solenoid valve coil

FWD

forward gear indicator LED diode

EV8

lowering solenoid valve coil

HANDBRAKE LED EV10

handbrake LED diode proportional solenoid valve coil

DRIVE MOT. TEMP. LED. drive motor temperature LED diode

DZ

diode zener 6.2V 1W

EV3

training up solenoid valve coil

R10

resistor 47Kohm 1/4W 5%

R9

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resistor 8.2Kohm 1/4W 5%

TR3

transistor BC 546

EV4

training down solenoid valve coil

1

R 1.4 / 1.6 / 1.8 / 2.0

2

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R 1.4/1.6/1.8/2.0

ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü

Part No: 2794340

ELECTRIC

Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

Tab. 01 (continued)

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SERVICE

Section: ELECTRICAL SYSTEM

ELECTRIC

Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

Ref. R4 RS232 C1 R1 TR1 BZ1 R2 D2 D3 D4 D5 D6 DZ2 R8 LLC1 R7 RL2 TR2 D1 D2 R1 WB LLC2 NO D1 D2 R1 LLC3 NO D1 D2 R1 LLC4 NO D1 D2 R1

R 1.4 / 1.6 / 1.8 / 2.0

Component description resistor 100-ohm 1/4w 5% console connection capacitor 47uf 63v resistor 1K0hm 1/4w 5% transistor BDX53F reverse gear microswitch connection resistor 10Kohm 1/4w 5% diode 1N4004 diode 1N4004 diode 1N4004 diode 1N4004 diode 1N4004 diode zener 6.2V-1W resistor 47Kohm 1/4W 5% lifting/lowering lever resistor 8.2Kohm 1/4 5% relay 48V 5A transistor BC546 diode 1N4004 diode 1N4004

R 1.4/1.6/1.8/2.0

ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü

resistor revolving light truck forward/backward lever output not used diode diode resistor up/down training lever output not used diode diode resistor forward/backward travelling lift lever output not used diode diode resistor

Tab. 01

NOTE: All HYSTER component code numbers are given in the spare parts catalogue.

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Section: ELECTRICAL SYSTEM Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0 WIRING DIAGRAM (1/3) MOD. R 1.4/1.6/1.8/2.0

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Section: ELECTRICAL SYSTEM Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0 WIRING DIAGRAM (2/3) MOD. R 1.4/1.6/1.8/2.0

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Section: ELECTRICAL SYSTEM Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0 WIRING DIAGRAM (3/3) MOD. R 1.4/1.6/1.8/2.0

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Section: ELECTRICAL SYSTEM Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0 LOGIC ELEMENT INPUT DIAGRAM MOD. R 1.4/1.6/1.8/2.0

NOTE: By taking E8 to +48V the brake valve is controlled at 40V instead of 20V

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R 1.4 / 1.6 / 1.8 / 2.0

5 6 Date: April 99

Part No: 2794340

Page:

10f

Section: ELECTRICAL SYSTEM

SERVICE

Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0

INTERFACE CARD N.B. THE JUMPERS MUST NOT BE MOVED OUT OF THE POSITION SHOWN IN THE SCREEN PRINT

FUNCTION OF JUMPERS J-1) Sends the signal through the dead-man pedal to the lifting chopper HPRC (see diagram 2/3 branch 64).

J-2) Connects resistors on negative to supply PNP-type sensors. The steering gear limit switch sensors are the PNP type (see diagram 1/3 branch 24).

J-3) Not used (see diagram 2/3 branch 41).

J-4) Connected to the battery low shutdown relay, if moved it prevents shutdown (see diagram 2/3 branch 57/58).

J-5) Makes the connection of the revolving light between the dead-man push-button and the accelerator (see diagram 2/3 branch 62). It is connected as standard to the dead-man push-button.

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5 6 Date: April 99

Part No: 2794340

Page:

10g

Section: ELECTRICAL SYSTEM

SERVICE

Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0 POSITION OF ELECTRIC COMPONENTS MOD. R 1.4/1.6/1.8/2.0

14

17

13

12

15 6

16 2

9

10 8 11 7 5

4

3

18

1

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5 6 Date: April 99

Part No: 2794340

Page:

10h

SERVICE

Section: ELECTRICAL SYSTEM Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0 ELECTRIC

1.0.1 TABLE OF POSITION OF ELECTRIC COMPONENTS MOD. R 1.4/1.6/1.8/2.0 The following table describes the various components shown on the previous page.

Key: Ref. Component description R 1.4/1.6/1.8/2.0

Component reference on diagram Function attributed to component Component on the model indicated

Ref.

Component description

1

Pump motor

2

Driving motor

3

Steering motor

4

Brake pump pressure switch

5

Dead-man microswitch

6

Drive/hydraulic electronic panel

7

Emergency push-button

8

Horn push-button

9

Operation display

10

Key switch

11

Reverse gear

12

Hydraulic control lever kit

13

Battery socket/plug

14

Traversing carriage limit stop sensor

15

Drive control pedal

16

Drive control EPS-DC board

17

Tachometric dynamo

18

Steering sensor

R 1.4/1.6/1.8/2.0

ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü

Tab. 02

NOTE: All HYSTER component code numbers are given in the spare parts catalogue.

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Date: April 99

Part No: 2794340

Page: 11

SERVICE

Section: ELECTRICAL SYSTEM

ELECTRIC

Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0

1.1 DRIVE/LIFTING ELECTRONIC PANEL COMPONENTS MOD. R 1.4/1.6/1.8/2.0

6/7 5

1

3 10/11 8/9 2

14 12/13

4

15

Page: 12

Part No: 2794340

Date: April 99

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SERVICE

Section: ELECTRICAL SYSTEM Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

R 1.4 / 1.6 / 1.8 / 2.0 ELECTRIC

1.1.1 TABLE OF ASSEMBLY OF DRIVE/LIFTING ELECTRONIC PANEL COMPONENTS MOD. R 1.4/1.6/1.8/2.0 The following table describes the various components shown on the previous page.

Key: Ref. Component description R 1.4/1.6/1.8/2.0

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Component reference on diagram Function attributed to component Component on the model indicated

Component description Electronic drive control SEM2D Electronic lifting control Main contactor Pump by-pass contactor Fuse 50A Fuse 300A Fuse 300A Fuse 7A Fuse 7A Fuse 5A Fuse 5A Fuse 3A Fuse 3A Interface card Battery proximity sensor

R 1.4/1.6/1.8/2.0

ü ü ü ü ü ü ü ü ü ü ü ü ü ü ü Tab. 03

NOTE: All HYSTER component code numbers are given in the spare parts catalogue.

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Date: April 99

Part No: 2794340

Page: 13

SERVICE

Section: ELECTRICAL SYSTEM

R 1.4 / 1.6 / 1.8 / 2.0

ELECTRIC

Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla

1.2 ELECTRIC STEERING SYSTEM MOD. R 1.4/1.6/1.8/2.0 4

1

5

6

2

3

+ BAT.

- BAT. 1.2.1

TABLE OF ELECTRIC STEERING SYSTEM COMPONENTS ASSEMBLY MOD. R 1.4/1.6/1.8/2.0

The following table describes the various components shown in the figure.

Key: Ref. Component description R 1.4/1.6/1.8/2.0

Ref. 1 2 3 4 5 6

Component reference on diagram Function attributed to component Component on the model indicated

Component description

R 1.4/1.6/1.8/2.0

ü ü ü ü ü ü

Electric guide panel Speedometer dynamo Electric steering gear motor Steering limit stop sensor Steering wheel Chain guide pinion

Tab. 04

NOTE: All HYSTER component code numbers are given in the spare parts catalogue.

Page: 14

Part No: 2794340

Date: April 99

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SERVICE

Section: ELECTRICAL SYSTEM

R 1.4 / 1.6 / 1.8 / 2.0

1.3 ELECTRONIC CONTROL DRIVE MOTOR CHOPPER SEM2 MOD. R 1.4/1.6/1.8/2.0 PRESENTATION The chopper SEM2, used to handle and control the drive motor, is the latest development in highfrequency MOS technology working at a frequency of 16 KHz.

It is an electronic system to control motors with separate energizing.

The armature and field are controlled by the system separately and so the current flowing in the field is not the same as the one flowing through the armature.

The lack of starting contactors, the winding and the field are controlled directly by MOSFET; metal oxide semiconductor field effect transistor.

The high switching frequency of the MOSFET, the separate energizing motor coupled with the SEM2 makes it possible to maintain the same speed even with a load A) Demand for higher torque B) More current on the motor There is only a supply contactor

SPECIFICATIONS

- Working voltage - Maximum field current - Maximum armature current (values set for R models) - Armature switching frequency - Field switching frequency - Maximum ambient temperature - Maximum ambient temperature

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24-48 Volt 50 A 350 A 16 KHz 1 KHz -30°C +80°C

5

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Date: April 99

Part No: 2794340

Page: 15

ELECTRIC

Truck Model / Carrello Tipo / Chariot Modele / Staplertyp / Tipo de carretilla