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

Download Complete Service Repair Manual for Hyster A462 (T10 T12 T15) Forklift

This Factory Service Repair Manual offers all the service and repair information about Hyster A462 (T10 T12 T15) Forklift The information on this manual covered everything you need to know when you want to repair or service Hyster A462 (T1

0 T12 T15) Forklift

Models Covered:

This manual is INSTANT DOWNLOAD

It means no shipping cost or waiting for getting a CD package for several days you will receive this manual today via instant download on completion of payment via our secure payment processor

This service manual is in html Format

Manual Contents:

INDEX

Section: ELECTRICAL SYSTEM
STANDARD ELECTRICAL DIAGRAMS
FUNCTIONAL ELECTRICAL DIAGRAM WITH WIRE GUIDANCE SYSTEM MODELS T1

0 12 15
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 12 15
STANDARD FUNCTIONAL ELECTRICAL DIAGRAM MODELS T10 12 15 MODELS T10 12 15
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
11 ELECTRICAL COMPONENTS
12 POSITION OF RELAYS BANK
13 DESCRIPTION OF RELAY FUNCTIONS
COMBI-C1 CONTROLLER
10 DESCRIPTION OF COMBI-C1 ELECTRONIC CONTROLLER
12 TECHNICAL SPECIFICATIONS
1

3 SCHEMATIC DIAGRAM
14 FUNCTIONAL CHARACTERISTICS
15 COMPENSATION CONCEPT
17 GENERAL WARNINGS AND PRECAUTIONS
20 POWER AND CONTROL CIRCUIT CONNECTORS
26 POWER CABLES CONNECTION DIAGRAM
30 PROGRAMMING CONSOLE
4

0 CONSOLE FUNCTIONS MAP
50 CONTROLLER PROGRAMMING
51 CONFIG MENU SET OPTIONS
52 CONFIG MENU ADJUSTMENT
53 MAIN MENU PARAMETER CHANGE
54 MAIN MENU TESTER
55 MAIN MENU SAVE PARAMETER
56 MAIN MENU RESTORE PARAMETER
5

7 MAIN MENU ALARM
58 MAIN MENU PROGRAM VACC
60 COMBI-C1 CONTROLLER CONFIGURATION TABLES
70 CALIBRATION SEQUENCE FOR INITIALIZATION OF A NEW CONTROLLER
72 PUMP UNIT CALIBRATION SEQUENCE
80 TROUBLESHOOTING
8

1 DECODING TRACTION SYSTEM DIAGNOSTIC LED ALARM SIGNALS
82 DECODING OF ALARMS DISPLAYED ON THE CONSOLE (TRACTION)
91 DECODING OF PUMP UNIT DIAGNOSTIC LED ALARMS
92 DECODING OF ALARMS DISPLAYED ON THE CONSOLE (PUMP UNIT)
PRC HYDRAULIC CONTROLLER
1

0 INTRODUCTION TO PRC CONTROLLER
20 CONSOLE FUNCTIONS MAP
30 PRC CONTROLLER CONFIGURATION TABLE
40 CONFIGURATION OF POTENTIOMETERS ON PRC
41 DESCRIPTION OF PARAMETERS
50 DESCRIPTION OF ALARMS
60 PROGRAM VACC
Section: HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
1

0 FUNCTIONAL HYDRAULIC DIAGRAM
11 TABLE OF HYDRAULIC COMPONENTS
12 TABLE OF HYDRAULIC COMPONENTS
13 MAST LIFT HYDRAULIC CIRCUIT STATUS
14 MAST LOWER HYDRAULIC CIRCUIT STATUS
15 FORKS RIGHT-HAND SIDESHIFT HYDRAULIC CIRCUIT STATUS
1

6 FORKS LEFT-HAND SIDESHIFT HYDRAULIC CIRCUIT STATUS
17 FORKS RIGHT-HAND ROTATION HYDRAULIC CIRCUIT STATUS
18 FORKS LEFT-HAND ROTATION HYDRAULIC CIRCUIT STATUS
20 MAST LIFT/LOWER AND LOAD HANDLER CONTROL VALVES
2

1 TABLE OF VALVE COMPONENTS
Section: LOAD HANDLER
THREE-SIDED LOAD HANDLER
10 STANDARD LOAD HANDLER COMPONENTS
11 TABLE OF STANDARD LOAD HANDLER COMPONENTS
12 COMPONENTS OF LOAD HANDLER WITH CARRIAGE
1

3 TABLE OF LOAD HANDLER COMPONENTS WITH CARRIAGE
20 LOAD HANDLER FUNCTION
21 INSTALLATION OF LOAD HANDLER WITH CARRIAGE
22 MECHANICAL ADJUSTMENT OF LIMIT POSITIONS
25 MAINTENANCE
26 TROUBLESHOOTING
3

0 MECHANICAL ADJUSTMENT OF THE LOAD HANDLER BEARINGS
Section: TRUCK INSTALLATION
10 INSTALLING THE TRUCK
20 TRUCK OPERATING CONDITIONS OUTSIDE AND INSIDE AISLE
21 DESCRIPTION OF TRUCK OPERATION OUTSIDE AND INSIDE AISLE
3

0 INSTALLING TRUCK IN AISLE
40 WIDE GUIDANCE ADJUSTMENT PROCEDURE
50 LAYOUT FOR POSITIONING OF MAGNETS IN AISLE
60 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
11 TABLE OF REDUCTION GEAR COMPONENTS
12 GENERAL
121 REDUCTION GEAR COMPONENTS
20 SERVICING PRODUCTS
21 CLEANING PRODUCTS
22 ASSEMBLY PRODUCTS
31 STANDARD TOOLS AND INSTRUMENTS
3

2 MEASURING INSTRUMENTS
40 DISASSEMBLY
41 INTRODUCTION
42 REMOVING AND DISASSEMBLY OF THE UPPER PART OF THE REDUCTION GEAR CASE
43 REMOVING OF THE REDUCTION GEAR COVER
44 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
46 REMOVING THE PINION SHAFT
47 REMOVING OF THE TAPER ROLLER BEARING OUTER RACE FROM THE REDUCTION GEAR CASE
48 REMOVING OF THE THREAD GUARD
5

0 ASSEMBLY
51 INTRODUCTION
61 MEASURING PINION SHAFT ASSEMBLY CLEARANCE
62 PRE-ASSEMBLY OF THE REDUCTION GEAR CASE
63 PRE-ASSEMBLY OF THE PINION SHAFT
64 ASSEMBLY OF THE CROWN WHEEL BEARING INNER RACE
6

5 PRE-ASSEMBLY OF THE PINION SHAFT
66 INSTALLING THE PINION SHAFT IN THE REDUCTION GEAR CASE
67 MEASURING PINION SHAFT BEARING CLEARANCE AND ADJUSTMENT OF THE PRELOAD VALUE
68 INSTALLING THE AXLE SHAFT AND GEAR IN THE REDUCTION GEAR CASE
6

9 MEASUREMENT AND ADJUSTMENT OF CROWN WHEEL BACKLASH
610 CHECKING TOOTH CONTACT
611 MEASURING CLEARANCE OF THE AXLE SHAFT BEARINGS AND ADJUSTING THE BEARING PRELOAD VALUE
612 FITTING THE THREAD GUARD ON THE REDUCTION GEAR CASE
6

13 FITTING THE RADIAL SHAFT SEAL IN THE REDUCTION GEAR CASE
614 FITTING THE COVER OF THE REDUCTION GEAR CASE
615 REDUCTION GEAR UPPER SECTION
71 ADJUSTMENT DATA
72 TIGHTENING TORQUES
80 TROUBLESHOOTING
9

0 INSTALLING THE REDUCTION GEAR ON THE TRUCK

Section: VERTICAL REDUCTION GEAR GR-96-97
10 SERVICING PRODUCTS
11 CLEANING PRODUCTS
12 ASSEMBLY PRODUCTS
20 COMPONENTS OF REDUCTION GEAR GR-96
21 TABLE OF REDUCTION GEAR COMPONENTS MODEL GR-96
2

2 COMPONENTS OF REDUCTION GEAR GR-97
23 TABLE OF REDUCTION GEAR COMPONENTS MODEL GR-97
30 TOOLS FOR DISMANTLING AND REASSEMBLING THE REDUCTION GEAR
40 SECTION OF COMPLETE REDUCTION GEAR GR-96 GR-97
50 DISMANTLING AND REASSEMBLING THE REDUCTION GEAR
6

0 ASSEMBLY
61 INTRODUCTION
62 ASSEMBLY
70 INSTALLING THE REDUCTION GEAR ON THE TRUCK
80 TROUBLESHOOTING

Section: VERTICAL REDUCTION GEAR GR-92
10 SERVICING PRODUCTS
11 CLEANING PRODUCTS
1

2 ASSEMBLY PRODUCTS
20 REDUCTION GEAR COMPONENTS
21 TABLE OF REDUCTION GEAR COMPONENTS
31 SPECIAL TOOLS FOR FITTING COMPONENTS
32 REDUCTION GEAR SECURED TO TOOL FOR DISASSEMBLY
40 DISMANTLING THE REDUCTION GEAR
4

1 SPECIAL EQUIPMENT REQUIRED
42 STANDARD TOOLS REQUIRED
43 TABLE OF SCREW AND NUT TIGHTENING TORQUES
50 ASSEMBLY OF COMPONENTS
51 INTRODUCTION
52 FITTING THE PINION TAPER ROLLER BEARINGS OUTER RACES
5

3 FITTING THE TAPER ROLLER BEARING TO THE PINION
54 FITTING THE TAPER ROLLER BEARING ON THE CYLINDRICAL CROWN WHEEL AND ASSEMBLY OF PINION AND CROWN WHEEL
55 FITTING THE WEEL STUDS TO THE AXLE SHAFT
56 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
58 FITTING THE STEERING THRUST BEARING COMPLETE ASSEMBLY OF THE REDUCTION GEAR
60 INSTALLING THE REDUCTION GEAR ON THE TRUCK
61 FILLING THE REDUCTION GEAR WITH OIL
7

0 TROUBLESHOOTING

LEVEL PRESELECTOR:

Section: INDEX
100 INTRODUCTION
101 NEXUS MULTIFUNCTION CONTROLLER
200 WIRING DIAGRAM SYMBOL LEGEND
FUNCTIONAL WIRING DIAGRAMS
FUNCTIONAL WIRING DIAGRAM MOD

T 10-12-15
FUNCTIONAL ELECTRIC DIAGRAM SOLENOID VALVE CONTROL MOD T 10-12-15
FUNCTIONAL ELECTRIC DIAGRAM OF LEVEL PRESELECTOR CONNECTION MOD T 10-12-15
FUNCTIONAL ELECTRIC DIAGRAM MOD T 10-12-15
CONNECTOR CONNECTION TABLE MOD

T 10-12-15
ELECTRIC DIAGRAM OF LEVEL PRESELECTOR CONNECTION MOD T 10-12-15
202 TABLE OF ELECTRIC COMPONENTS
ELECTRIC COMPONENTS FOR PRESELECTOR WORKING
300 PRESELECTOR PROGRAMMING
400 LEVEL HEIGHT PROGRAMMING
5

00 PRESELECTOR AUTOMATIC USE DURING PICKING AND DEPOSIT OPERATIONS
501 AUTOMATIC PICKING CYCLE ON THE UPPER LEVELS
502 AUTOMATIC DEPOSIT CYCLE TO THE GROUND BY DESCENDING
503 AUTOMATIC PICKING CYCLE FROM THE GROUND
5

04 AUTOMATIC DEPOSIT CYCLE ON THE UPPER LEVELS BY RISING
600 ALARMS

DC-EPS POWER STEERING AND WIRE GUIDANCE:

Section: QUICK SET-UP PROCEDURE
10 PRELIMINARY SET-UP PROCEDURE
20 STEER SYSTEM SET-UP PROCEDURE
2

1 RTC (RETURN TO CENTER) SYSTEM
211 WHEN IS IT NECESSARY TO CARRY OUT THIS PROCEDURE ?
21 SYSTEM WITH TACH GENERATOR
211 WHEN IS IT NECESSARY TO CARRY OUT THIS PROCEDURE ?
30 WIRE GUIDANCE SYSTEM SET UP (COMPLETE PROCEDURE)
3

1 WHEN IS IT NECESSARY TO CARRY OUT THIS PROCEDURE ?
40 WIRE GUIDANCE SYSTEM ADJUSTMENT (PROCEDURE TO CARRY OUT ON DELIVERY OF A NEW TRUCK WITH STANDARD FACTORY SETTINGS)

Section: STEERING AND WIRE GUIDANCE
1

0 INTRODUCTION
20 EQUIPMENT FOR ADJUSTMENT
21 SYSTEM COMPONENTS
21A TWO INDUCTIVE WIRE SENSORS
21B STEER ANGLE POSITION POTENTIOMETER (MDU POT)
21C STEERING SERVO MOTOR CONTROL UNIT
21D OPERATOR CONSOLE
2

1E STEERING SERVO MOTOR
21F STEERING HANDLE
21G LINE DRIVER (GUIDE WIRE SIGNAL GENERATOR)
21G SIGNAL STRENGTH SET UP
22 ELECTRICAL SPECIFICATIONS
30 STEERING REDUCTION RATIO
31 INSTALLING SENSORS
4

0 SYSTEM DESCRIPTION
40A AUTOMATIC WIRE GUIDED STEERING
40B MANUAL STEERING WITH TACHO GENERATOR
40C MANUAL STEERING WITH POTENTIOMETER
40D WIRE GUIDED STEERING OPERATING SEQUENCE
50 POWER CONNECTION DIAGRAM
5

1 TACHO HANDWHEEL STEERING PLUS WIRE GUIDANCE ELECTRICAL DRAWING
52 TACHO-GENERATOR STEERING WHEEL AND AUTOMATIC CENTERING
53 POT (SMART STEER) CONTROLLED STEERING PLUS WIRE GUIDANCE ELECTRICAL DRAWING
54 POT (SMART STEER) CONTROLLED STEERING
5

5 PRELIMINARY SET UP PROCEDURE
60 DESCRIPTION OF ECM CONNECTORS
61 ECM CONNECTOR D DESCRIPTION
61A AUDIBLE AND VISUAL SIGNALS (MANLED AUTOLED BUZZER +12V)
61B AUTOMATIC MODE REQUEST (AUTOSEL GND)
6

1D CONNECTIONS TO THE DRIVE SYSTEM (MA MI A1 A2)
61E LIMIT MICROSWITCH CONNECTION (CLS CCLS)
62 MOTHERBOARD CONNECTOR E DESCRIPTION
70 DESCRIPTION OF WIRE GUIDANCE CARD CONNECTIONS
80 SETTING ECM ACSZPA0B
8

0A SETTING THE MAXIMUM CURRENT (IMAX)
80B SETTING TACHOMETRIC FEEDBACK
80C SETTING THE MANUAL STEERING
90 WIRE GUIDANCE CARD ACSZPB0B
90A TRACTION PLUG SENSING SETTING
90B MDU GUIDANCE SENSOR SETTINGS
9

0C MDU POT OFFSET ADJUSTMENT
90D STEERING ERROR OFFSET ADJUSMENT
90E STEER CORRECTION RESPONSE ADJUSTMENT POTENTIOMETRIC FEEDBACK)
90F GAIN LOOP ADJUSTMENT
90G LOAD END SENSOR ADJUSTMENT
90H LOAD END TRAVEL MDU SENSOR WEIGHT ADJUSTMENT
(WEIGHTED SETTING OF ANTENNAS WHEN TRAVELING LOAD WHEEL DIRECTION)
9

0I ACQUISITION ANGLE ADJUSTMENT
90L GUIDANCE ALARM TOLERANCE ADJUSTMENT
90M MAXIMUM WIRE GUIDANCE STEERING ANGLE ADJUSTMENT (POT OUT OF RANGE ALARM)
100 TIP ON SETTING UP
100A REVERSED MDU POT FEEDBACK
10

0B REVERSED SENSOR FEEDBACK
110 ALARMS AND TROUBLE SHOOTING
111 DESCRIPTION OF FUSES
112 DESCRIPTION OF ALARMS
112A MANUAL MODE ALARMS
112B WIRE GUIDANCE MODE ALARMS
120 HAND SET DESCRIPTION
12

0A TACH-GENERATOR STEERING OPTION HAND SET FUNCTION MAP
120B POT STEERING OPTION HAND SET FUNCTION MAP
121 MAIN MENU PARAMETERS LIST
122 MAIN MENU: TESTER FUNCTIONS
123 MAIN MENU: ALARMS FUNCTIONS
12

4 CONFIG MENU: SET OPTIONS FUNCTION LIST
125 CONFIG MENU: ADJUSTMENTS FUNCTION LIST
130 HARDWARE FAILURE DETECTION
130A HARDWARE FAILURE DETECTION IN MANUAL STEERING
130B HARDWARE FAILURE DETECTION IN AUTOMATIC STEERING
14

0 PERIODIC MAINTENANCE
150 WIRE GUIDANCE DIAGNOSTICS

This manual can be used by anyone from a first time owner/amateur to a professional technician

Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawingsKeep this manual handy and use it often Performing routine preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs

Your will receive a download link immediately after your payment is completed successfully So please make sure your email address is correctCheck spam if cant find the new mesage in your email inbox

File Format: HTML
Compatible: All Versions of Windows & Mac
Language: English