Hyster A462 (T1.0 , T1.2 , T1.5) Forklift Service Repair Manual

Download Full Service Workshop Repair Manual for Hyster A462 (T1.0 , T1.2 , T1.5) Forklift.

This Workshop Service Manual offers all the service and repair information about Hyster A462 (T1.0 , T1.2 , T1.5) Forklift. The information on this manual covered everything you need to know when you want to repair or service Hyster A462 (T1.0 , T1.2 , T1.5) Forklift.

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Manual Contents:

INDEX

Section: ELECTRICAL SYSTEM
– STANDARD ELECTRICAL DIAGRAMS
– FUNCTIONAL ELECTRICAL DIAGRAM WITH WIRE GUIDANCE SYSTEM MODELS T1.0 – 1.2 – 1.5
– FUNCTIONAL ELECTRICAL DIAGRAM OF THE SOLENOID VALVES PRC CONTROLLER
– FUNCTIONAL ELECTRICAL DIAGRAM
– FUNCTIONAL ELECTRICAL DIAGRAM OF ELECTRIC STEERING WITH WIRE GUIDANCE SYSTEM
– KEY TO ELECTRICAL AND CONNECTOR DIAGRAMS
– ELECTRICAL COMPONENTS MODELS T1.0 – 1.2 – 1.5
– STANDARD FUNCTIONAL ELECTRICAL DIAGRAM MODELS T1.0 – 1.2 – 1.5 MODELS T1.0 – 1.2 – 1.5
– FUNCTIONAL ELECTRICAL DIAGRAM OF THE SOLENOID VALVES PRC CONTROLLER
– FUNCTIONAL ELECTRICAL DIAGRAM
– KEY TO ELECTRICAL DIAGRAMS OF COMPONENTS
– ELECTRICAL DIAGRAMS WITH WIRE GUIDANCE
1.0 TABLE OF ELECTRICAL COMPONENTS
1.1 ELECTRICAL COMPONENTS
1.2 POSITION OF RELAYS BANK
1.3 DESCRIPTION OF RELAY FUNCTIONS
COMBI-C1 CONTROLLER
1.0 DESCRIPTION OF COMBI-C1 ELECTRONIC CONTROLLER
1.2 TECHNICAL SPECIFICATIONS
1.3 SCHEMATIC DIAGRAM
1.4 FUNCTIONAL CHARACTERISTICS
1.5 COMPENSATION CONCEPT
1.7 GENERAL WARNINGS AND PRECAUTIONS
2.0 POWER AND CONTROL CIRCUIT CONNECTORS
2.6 POWER CABLES CONNECTION DIAGRAM
3.0 PROGRAMMING CONSOLE
4.0 CONSOLE FUNCTIONS MAP
5.0 CONTROLLER PROGRAMMING
5.1 CONFIG. MENU SET OPTIONS
5.2 CONFIG. MENU ADJUSTMENT
5.3 MAIN MENU PARAMETER CHANGE
5.4 MAIN MENU TESTER
5.5 MAIN MENU SAVE PARAMETER
5.6 MAIN MENU RESTORE PARAMETER
5.7 MAIN MENU ALARM
5.8 MAIN MENU PROGRAM VACC
6.0 COMBI-C1 CONTROLLER CONFIGURATION TABLES
7.0 CALIBRATION SEQUENCE FOR INITIALIZATION OF A NEW CONTROLLER
7.2 PUMP UNIT CALIBRATION SEQUENCE
8.0 TROUBLESHOOTING
8.1 DECODING TRACTION SYSTEM DIAGNOSTIC LED ALARM SIGNALS
8.2 DECODING OF ALARMS DISPLAYED ON THE CONSOLE (TRACTION)
9.1 DECODING OF PUMP UNIT DIAGNOSTIC LED ALARMS
9.2 DECODING OF ALARMS DISPLAYED ON THE CONSOLE (PUMP UNIT)
– PRC HYDRAULIC CONTROLLER
1.0 INTRODUCTION TO PRC CONTROLLER
2.0 CONSOLE FUNCTIONS MAP
3.0 PRC CONTROLLER CONFIGURATION TABLE
4.0 CONFIGURATION OF POTENTIOMETERS ON PRC
4.1 DESCRIPTION OF PARAMETERS
5.0 DESCRIPTION OF ALARMS
6.0 PROGRAM VACC
Section: HYDRAULIC SYSTEM
– HYDRAULIC SYSTEM
1.0 FUNCTIONAL HYDRAULIC DIAGRAM
1.1 TABLE OF HYDRAULIC COMPONENTS
1.2 TABLE OF HYDRAULIC COMPONENTS
1.3 MAST LIFT – HYDRAULIC CIRCUIT STATUS
1.4 MAST LOWER – HYDRAULIC CIRCUIT STATUS
1.5 FORKS RIGHT-HAND SIDESHIFT – HYDRAULIC CIRCUIT STATUS
1.6 FORKS LEFT-HAND SIDESHIFT – HYDRAULIC CIRCUIT STATUS
1.7 FORKS RIGHT-HAND ROTATION HYDRAULIC CIRCUIT STATUS
1.8 FORKS LEFT-HAND ROTATION HYDRAULIC CIRCUIT STATUS
2.0 MAST LIFT/LOWER AND LOAD HANDLER CONTROL VALVES
2.1 TABLE OF VALVE COMPONENTS
Section: LOAD HANDLER
– THREE-SIDED LOAD HANDLER
1.0 STANDARD LOAD HANDLER COMPONENTS
1.1 TABLE OF STANDARD LOAD HANDLER COMPONENTS
1.2 COMPONENTS OF LOAD HANDLER WITH CARRIAGE
1.3 TABLE OF LOAD HANDLER COMPONENTS WITH CARRIAGE
2.0 LOAD HANDLER FUNCTION
2.1 INSTALLATION OF LOAD HANDLER WITH CARRIAGE
2.2 MECHANICAL ADJUSTMENT OF LIMIT POSITIONS
2.5 MAINTENANCE
2.6 TROUBLESHOOTING
3.0 MECHANICAL ADJUSTMENT OF THE LOAD HANDLER BEARINGS
Section: TRUCK INSTALLATION
1.0 INSTALLING THE TRUCK
2.0 TRUCK OPERATING CONDITIONS OUTSIDE AND INSIDE AISLE
2.1 DESCRIPTION OF TRUCK OPERATION OUTSIDE AND INSIDE AISLE
3.0 INSTALLING TRUCK IN AISLE
4.0 WIDE GUIDANCE ADJUSTMENT PROCEDURE
5.0 LAYOUT FOR POSITIONING OF MAGNETS IN AISLE
6.0 LAYOUT FOR POSITIONING OF GUIDES IN AISLE

REDUCTION GEAR
SERIES HFK 100 – 200 400 – 600
SERIES GR 92 – 96 – 97

Section: VERTICAL REDUCTION GEAR HFK 100-200-400-600
1.0 REDUCTION GEAR COMPONENTS
1.1 TABLE OF REDUCTION GEAR COMPONENTS
1.2 GENERAL
1.2.1 REDUCTION GEAR COMPONENTS
2.0 SERVICING PRODUCTS
2.1 CLEANING PRODUCTS
2.2 ASSEMBLY PRODUCTS
3.1 STANDARD TOOLS AND INSTRUMENTS
3.2 MEASURING INSTRUMENTS
4.0 DISASSEMBLY
4.1 INTRODUCTION
4.2 REMOVING AND DISASSEMBLY OF THE UPPER PART OF THE REDUCTION GEAR CASE
4.3 REMOVING OF THE REDUCTION GEAR COVER
4.4 REMOVING THE CROWN WHEEL AND AXLE SHAFT
4.5 REMOVING THE INNER RACE OF THE TAPER ROLLER BEARING FROM THE AXLE SHAFT AND THE CROWN WHEEL
4.6 REMOVING THE PINION SHAFT
4.7 REMOVING OF THE TAPER ROLLER BEARING OUTER RACE FROM THE REDUCTION GEAR CASE
4.8 REMOVING OF THE THREAD GUARD
5.0 ASSEMBLY
5.1 INTRODUCTION
6.1 MEASURING PINION SHAFT ASSEMBLY CLEARANCE
6.2 PRE-ASSEMBLY OF THE REDUCTION GEAR CASE
6.3 PRE-ASSEMBLY OF THE PINION SHAFT
6.4 ASSEMBLY OF THE CROWN WHEEL BEARING INNER RACE
6.5 PRE-ASSEMBLY OF THE PINION SHAFT
6.6 INSTALLING THE PINION SHAFT IN THE REDUCTION GEAR CASE
6.7 MEASURING PINION SHAFT BEARING CLEARANCE AND ADJUSTMENT OF THE PRELOAD VALUE
6.8 INSTALLING THE AXLE SHAFT AND GEAR IN THE REDUCTION GEAR CASE
6.9 MEASUREMENT AND ADJUSTMENT OF CROWN WHEEL BACKLASH
6.10 CHECKING TOOTH CONTACT
6.11 MEASURING CLEARANCE OF THE AXLE SHAFT BEARINGS AND ADJUSTING THE BEARING PRELOAD VALUE
6.12 FITTING THE THREAD GUARD ON THE REDUCTION GEAR CASE
6.13 FITTING THE RADIAL SHAFT SEAL IN THE REDUCTION GEAR CASE
6.14 FITTING THE COVER OF THE REDUCTION GEAR CASE
6.15 REDUCTION GEAR UPPER SECTION
7.1 ADJUSTMENT DATA
7.2 TIGHTENING TORQUES
8.0 TROUBLESHOOTING
9.0 INSTALLING THE REDUCTION GEAR ON THE TRUCK

Section: VERTICAL REDUCTION GEAR GR-96-97
1.0 SERVICING PRODUCTS
1.1 CLEANING PRODUCTS
1.2 ASSEMBLY PRODUCTS
2.0 COMPONENTS OF REDUCTION GEAR GR-96
2.1 TABLE OF REDUCTION GEAR COMPONENTS, MODEL GR-96
2.2 COMPONENTS OF REDUCTION GEAR GR-97
2.3 TABLE OF REDUCTION GEAR COMPONENTS, MODEL GR-97
3.0 TOOLS FOR DISMANTLING AND REASSEMBLING THE REDUCTION GEAR
4.0 SECTION OF COMPLETE REDUCTION GEAR GR-96 GR-97
5.0 DISMANTLING AND REASSEMBLING THE REDUCTION GEAR
6.0 ASSEMBLY
6.1 INTRODUCTION
6.2 ASSEMBLY
7.0 INSTALLING THE REDUCTION GEAR ON THE TRUCK
8.0 TROUBLESHOOTING

Section: VERTICAL REDUCTION GEAR GR-92
1.0 SERVICING PRODUCTS
1.1 CLEANING PRODUCTS
1.2 ASSEMBLY PRODUCTS
2.0 REDUCTION GEAR COMPONENTS
2.1 TABLE OF REDUCTION GEAR COMPONENTS
3.1 SPECIAL TOOLS FOR FITTING COMPONENTS
3.2 REDUCTION GEAR SECURED TO TOOL FOR DISASSEMBLY
4.0 DISMANTLING THE REDUCTION GEAR
4.1 SPECIAL EQUIPMENT REQUIRED
4.2 STANDARD TOOLS REQUIRED
4.3 TABLE OF SCREW AND NUT TIGHTENING TORQUES
5.0 ASSEMBLY OF COMPONENTS
5.1 INTRODUCTION
5.2 FITTING THE PINION TAPER ROLLER BEARINGS OUTER RACES
5.3 FITTING THE TAPER ROLLER BEARING TO THE PINION
5.4 FITTING THE TAPER ROLLER BEARING ON THE CYLINDRICAL CROWN WHEEL AND ASSEMBLY OF PINION AND CROWN WHEEL
5.5 FITTING THE WEEL STUDS TO THE AXLE SHAFT
5.6 FITTING THE TAPER ROLLER BEARINGS ON THE BEVEL CROWN WHEEL – FITTING THE TAPER ROLLER BEARINGS ON THE FLANGE
5.7 FITTING THE FLANGE AND BEVEL CROWN WHEEL TO THE AXLE SHAFT
5.8 FITTING THE STEERING THRUST BEARING, COMPLETE ASSEMBLY OF THE REDUCTION GEAR
6.0 INSTALLING THE REDUCTION GEAR ON THE TRUCK
6.1 FILLING THE REDUCTION GEAR WITH OIL
7.0 TROUBLESHOOTING

LEVEL PRESELECTOR:

Section: INDEX
1.00 INTRODUCTION
1.01 NEXUS MULTIFUNCTION CONTROLLER
2.00 WIRING DIAGRAM SYMBOL LEGEND
FUNCTIONAL WIRING DIAGRAMS
– FUNCTIONAL WIRING DIAGRAM MOD. T 1.0-1.2-1.5
– FUNCTIONAL ELECTRIC DIAGRAM SOLENOID VALVE CONTROL MOD. T 1.0-1.2-1.5
– FUNCTIONAL ELECTRIC DIAGRAM OF LEVEL PRESELECTOR CONNECTION MOD. T 1.0-1.2-1.5
– FUNCTIONAL ELECTRIC DIAGRAM MOD. T 1.0-1.2-1.5
– CONNECTOR CONNECTION TABLE MOD. T 1.0-1.2-1.5
– ELECTRIC DIAGRAM OF LEVEL PRESELECTOR CONNECTION MOD. T 1.0-1.2-1.5
2.02 TABLE OF ELECTRIC COMPONENTS
– ELECTRIC COMPONENTS FOR PRESELECTOR WORKING
3.00 PRESELECTOR PROGRAMMING
4.00 LEVEL HEIGHT PROGRAMMING
5.00 PRESELECTOR AUTOMATIC USE DURING PICKING AND DEPOSIT OPERATIONS
5.01 AUTOMATIC PICKING CYCLE ON THE UPPER LEVELS
5.02 AUTOMATIC DEPOSIT CYCLE TO THE GROUND BY DESCENDING
5.03 AUTOMATIC PICKING CYCLE FROM THE GROUND
5.04 AUTOMATIC DEPOSIT CYCLE ON THE UPPER LEVELS BY RISING
6.00 ALARMS

DC-EPS POWER STEERING AND WIRE GUIDANCE:

Section: QUICK SET-UP PROCEDURE
1.0 PRELIMINARY SET-UP PROCEDURE
2.0 STEER SYSTEM SET-UP PROCEDURE
2.1 RTC (RETURN TO CENTER) SYSTEM
2.1.1 WHEN IS IT NECESSARY TO CARRY OUT THIS PROCEDURE ?
2.1 SYSTEM WITH TACH. GENERATOR
2.1.1 WHEN IS IT NECESSARY TO CARRY OUT THIS PROCEDURE ?
3.0 WIRE GUIDANCE SYSTEM SET UP (COMPLETE PROCEDURE)
3.1 WHEN IS IT NECESSARY TO CARRY OUT THIS PROCEDURE ?
4.0 WIRE GUIDANCE SYSTEM ADJUSTMENT (PROCEDURE TO CARRY OUT ON DELIVERY OF A NEW TRUCK WITH STANDARD SETTINGS)

Section: STEERING AND WIRE GUIDANCE
1.0 INTRODUCTION
2.0 EQUIPMENT FOR ADJUSTMENT
2.1 SYSTEM COMPONENTS
2.1.A TWO INDUCTIVE WIRE SENSORS
2.1.B STEER ANGLE POSITION POTENTIOMETER (MDU POT)
2.1.C STEERING SERVO MOTOR CONTROL UNIT
2.1.D OPERATOR CONSOLE
2.1.E STEERING SERVO MOTOR
2.1.F STEERING HANDLE
2.1.G LINE DRIVER (GUIDE WIRE SIGNAL GENERATOR)
2.1.G SIGNAL STRENGTH SET UP
2.2 ELECTRICAL SPECIFICATIONS
3.0 STEERING REDUCTION RATIO
3.1 INSTALLING SENSORS
4.0 SYSTEM DESCRIPTION
4.0.A AUTOMATIC WIRE GUIDED STEERING
4.0.B MANUAL STEERING WITH TACHO GENERATOR
4.0.C MANUAL STEERING WITH POTENTIOMETER
4.0.D WIRE GUIDED STEERING OPERATING SEQUENCE
5.0 POWER CONNECTION DIAGRAM
5.1 TACHO HANDWHEEL STEERING PLUS WIRE GUIDANCE ELECTRICAL DRAWING
5.2 TACHO-GENERATOR STEERING WHEEL AND AUTOMATIC CENTERING
5.3 POT (SMART STEER) CONTROLLED STEERING PLUS WIRE GUIDANCE ELECTRICAL DRAWING
5.4 POT (SMART STEER) CONTROLLED STEERING
5.5 PRELIMINARY SET UP PROCEDURE
6.0 DESCRIPTION OF ECM CONNECTORS
6.1 ECM CONNECTOR “D” DESCRIPTION
6.1.A AUDIBLE AND VISUAL SIGNALS (MANLED, AUTOLED, BUZZER, +12V)
6.1.B AUTOMATIC MODE REQUEST (AUTOSEL, GND)
6.1.D CONNECTIONS TO THE DRIVE SYSTEM (MA, MI, A1, A2)
6.1.E LIMIT MICROSWITCH CONNECTION (CLS, CCLS)
6.2 MOTHERBOARD CONNECTOR “E” DESCRIPTION
7.0 DESCRIPTION OF WIRE GUIDANCE CARD CONNECTIONS
8.0 SETTING ECM ACSZPA0B
8.0.A SETTING THE MAXIMUM CURRENT (IMAX.)
8.0.B SETTING TACHOMETRIC FEEDBACK
8.0.C SETTING THE MANUAL STEERING
9.0 WIRE GUIDANCE CARD ACSZPB0B
9.0.A TRACTION PLUG SENSING SETTING
9.0.B MDU GUIDANCE SENSOR SETTINGS
9.0.C MDU POT OFFSET ADJUSTMENT
9.0.D STEERING ERROR OFFSET ADJUSMENT
9.0.E STEER CORRECTION RESPONSE ADJUSTMENT POTENTIOMETRIC FEEDBACK)
9.0.F GAIN LOOP ADJUSTMENT
9.0.G LOAD END SENSOR ADJUSTMENT
9.0.H LOAD END TRAVEL – MDU SENSOR WEIGHT ADJUSTMENT
(WEIGHTED SETTING OF ANTENNAS WHEN TRAVELING LOAD WHEEL DIRECTION)
9.0.I ACQUISITION ANGLE ADJUSTMENT
9.0.L GUIDANCE ALARM TOLERANCE ADJUSTMENT
9.0.M MAXIMUM WIRE GUIDANCE STEERING ANGLE ADJUSTMENT (POT OUT OF RANGE ALARM)
10.0 TIP ON SETTING UP
10.0.A REVERSED MDU POT FEEDBACK
10.0.B REVERSED SENSOR FEEDBACK
11.0 ALARMS AND TROUBLE SHOOTING
11.1 DESCRIPTION OF FUSES
11.2 DESCRIPTION OF ALARMS
11.2.A MANUAL MODE ALARMS
11.2.B WIRE GUIDANCE MODE ALARMS
12.0 HAND SET DESCRIPTION
12.0.A TACH-GENERATOR STEERING OPTION – HAND SET FUNCTION MAP
12.0.B POT STEERING OPTION – HAND SET FUNCTION MAP
12.1 MAIN MENU “PARAMETERS” LIST
12.2 MAIN MENU: TESTER FUNCTIONS
12.3 MAIN MENU’: “ALARMS” FUNCTIONS
12.4 CONFIG MENU’: “SET OPTIONS” FUNCTION LIST
12.5 CONFIG MENU: “ADJUSTMENTS” FUNCTION LIST
13.0 HARDWARE FAILURE DETECTION
13.0.A HARDWARE FAILURE DETECTION IN MANUAL STEERING
13.0.B HARDWARE FAILURE DETECTION IN AUTOMATIC STEERING
14.0 PERIODIC MAINTENANCE
15.0 WIRE GUIDANCE DIAGNOSTICS

This manual is appropriate for people with a range of degrees of knowledge, from novices and inexperienced owners to seasoned technicians. This manual’s step-by-step instructions are given in an easy-to-understand way with the help of images and drawings, making them understandable even to people with little prior experience. It is best to have this manual nearby and to refer to it frequently. You may successfully avoid early failures and needless repairs by regularly performing routine and preventive maintenance as directed, eventually saving significant time and money.

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