Hyster A465 / A469 (C1.8X V40XMU) Forklift Service Repair Manual

Download Complete Service Repair Manual for Hyster A465 (C18X V40XMU) Forklift

This Factory Service Repair Manual offers all the service and repair information about Hyster A465 (C18X V40XMU) Forklift The information on this manual covered everything you need to know when you want to repair or service Hyster A465 (C1

8X V40XMU) Forklift

Models Covered:

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Manual Contents:

INDEX

1

0 INTRODUCTION
Section: TRUCK INSTALLATION
10 INTRODUCTION
11 VNA INSTALATION
12 VNA UNPACKING AND SET UP
13 VNA DELIVERY
20 VNA REMOVAL FROM CONTAINER / TRUCK
30 VNA STAND UP PROCEDURE
40 LOWER CAB AFTER STAND UP
5

0 INSTALLATION OF ATTACHMENT
60 ADD OIL TO HYDRAULIC TANK
70A BATTERY INSTALLATION US: V30XMU V35XMU EU: C10 C13 C15B
70B BATTERY INSTALLATION US: V40XMU EU: C18X
80 INSTALLATION IN AISLE
8

1 LOAD UNIT DEPOSIT ADJUSTMENT
82 IMPORTANT (GUIDE ROLLERS / WIRE GUIDANCE)
90 OPERATOR TRAINING
Section: ELECTRICAL SYSTEM ELECTRIC STEERING SYSTEM EPS-DC
FOR FURTHER INFORMATION REGARDING THE ELECTRONIC SYSTEM OF THE EPS-DC ELECTRICAL STEERING SYSTEM CONSULT SERVICE MANUAL P/N 2795713
Section: ELECTRICAL SYSTEM
1

0 ELECTRICAL COMPARTMENT ARRANGEMENT MODELS V30XMU V35XMU C10 C13 C15B
101 ELECTRICAL COMPARTMENT ARRANGEMENT MODELS V40XMU C18X
11 DESCRIPTION OF COMPONENTS
111 PHOTOCELLS
111A PHOTOCELL ADJUSTMENT
1

11B MALFUNCTION CAUSED BY INCORRECT ADJUSTMENT
112 THROTTLE ASSEMBLY
113 BATTERY DISCHARGE INDICATOR (BDI)
113A LOCK OUT LEVEL ADJUSTMENT
113B BDI TROUBLESHOOTING
114 DC / DC CONVERTER
12 TABLE OF ELECTRICAL SYSTEM COMPONENTS
2

0 TRACTION MOTOR ELECTRONIC CONTROL
201 INTRODUCTION
21 DEFINITION OF THE TRUCK DIRECTION OF TRAVEL
22 CONTROLLER GENERAL FEATURES
23 CONTROLLER FUNCTIONAL FEATURES
24 CONTROLLER DIAGNOSTICS
25 CHOPPER H2B MECHANICAL DIAGRAM
2

6 CONNECTORS
27 CONNECTOR INCONNECTOR E INPUT DESCRIPTION
29 BASIC DIAGRAM OF THE TRACTION CONTROLLER CONNECTIONS
30 HAND SET
301 INTRODUCTION
32 USE OF THE HAND SET
321 CONNECTION TO CONTROLLER
4

0 CONSOLE FUNCTION CHART TRACTION MOTOR CONTROLLER
41 CONTROLLER PROGRAMMING
410 CONFIGURATION MENU
411 CONFIG MENU / SET MODEL
412 CONFIG MENU / SET OPTIONS
413 CONFIG MENU / ADJUSTMENT
414 MAIN MENU / PARAMET

CHANGE
415 MAIN MENU / TESTER
416 MAIN MENU / SAVE PARAMETER
417 MAIN MENU / RESTORE PARAM
418 MAIN MENU / ALARM
419 MAIN MENU / PROGRAM VACC
419 MAIN MENU / PROGRAM VACC
42 CONFIGURATION TABLES FOR TRACTION CONTROLLER
4

3 PROGRAMMING LEVELS CORRESPONDENCE TABLE
44 SET UP OF A NEW CONTROLLER BEFORE OPERATION
50 TROUBLESHOOTING
51 DECODING DIAGNOSTIC LED ALARM CODES FOR TRACTION CONTROLLER
52 DECODING HAND SET ALARMS FOR TRACTION CONTROLLER
6

0 PUMP MOTOR CONTROLLER DESCRIPTION
61 CONTROLLER FUNCTIONAL FEATURES
62 PUMP MOTOR CONTROLLER CIRCUIT
63 PUMP MOTOR CONTROLLER CONNECTORS
64 CONNECTOR INPUT DESCRIPTIONS (EXCEPT E)
65 CONNECTOR E INPUT DESCRIPTION
6

6A CONSOLE FUNCTION CHART PUMP MOTOR CONTROLLER
66 HAND SET PROGRAMMING OF THE PUMP MOTOR CONTROLLER
661 CONFIGURATION MENU
67 CONFIGURATION TABLE PUMP MOTOR CONTROLLER
68 PARAMETER VALUE VERSUS PROGRAMMED LEVEL TABLE
6

14 TROUBLESHOOTING
6141 DECODING DIAGNOSTIC LED ALARM CODES FOR PUMP CONTROLLER
6142 DECODING HAND SET ALARMS FOR PUMP MOTOR CONTROLLER
70 CONFIGURATION TABLES EPS ELECTRIC POWER STEERING CONTROLLER
71 EPS CONFIGURATION WITH SMART STEER (POT) STEERING
7

2 EPS CONFIGURATION WITH TACHO GENERATOR STEERING
Section: PLC
10 STANDARD INTERLOCK FUNCTIONS
20 ENABLE FUNCTION MANAGEMENT
21 DESCRIPTION OF THE SYSTEM THAT RUNS THE ENABLES PLC (PROGRAMMABLE LOGIC CONTROLLER)
2

2 GENERAL CHARACTERISTICS
30 PROGRAMMING
40 ELECTRIC ADJUSTMENT OF THE CAB AND AUXILIARY MAST LOWERING PROPORTIONAL ELECTRO-HYDRAULIC VALVES
50 PLC DIGITAL INPUT / OUTPUT REFERENCE EU / US VERSIONS
51A PLC TRUTH TABLE AND INTERFACE RELAY BOARD (US VERSION ONLY)
5

1B PLC TRUTH TABLE AND INTERFACE RELAY BOARD (EU VERSION ONLY)
60 REMOVING/INSTALLING THE PLC
70 PLC BATTERY FUNCTION AND CHANGING
82 PROCEDURE FOR CHANGING FUSES
Section: DIAGNOSTICS
10 CAB DOES NOT LOWER
2

0 FORKS DO NOT EXTEND LEFT
30 FORKS DO NOT EXTEND RIGHT
40 FORKS DO NOT LOWER
50 FORKS DO NOT RAISE
60 FORKS DO NOT RETRACT FROM LEFT
70 FORKS DO NOT RETRACT FROM RIGHT
80 FORKS DO NOT ROTATE LEFT
9

0 FORKS DO NOT ROTATE RIGHT
100 HIGH TEMPERATURE
110 MINI MAST DOES NOT TRAVERSE LEFT
120 MINI MAST DOES NOT TRAVERSE RIGHT
130 SYNC CAB / FORKS DO NOT LOWER
140 SYNC TRAVERSE / ROTATE DOES NOT WORK
15

0 TRUCK DOES NOT TRAVEL
Section: SLOW DOWN / STOP
10 AUTOMATIC SLOW DOWN AND STOP SYSTEM DESCRIPTION
11 MAGNET INSTALLATION IN AISLE
111 MAGNET LAYOUT FOR SYSTEMS WITH 2 MAGNETS IN AISLE
112 MAGNET LAYOUT FOR SYSTEMS WITH 4 MAGNETS IN AISLE
2

0 SYSTEM DESCRIPTIONS
21 (US) END OF AISLE AUTO-BRAKING
22 (EU) END OF AISLE AUTO-BRAKING
23 SLOW DOWN / STOP (SET / RESET)
30 SYSTEM FUNCTIONS (WITH STANDARD PLC PROGRAM)
31 SYSTEMS WITH 2 MAGNETS IN AISLE
3

2 SYSTEMS WITH 4 MAGNETS IN AISLE
40 TROUBLESHOOTING
Section:HYDRAULIC SYSTEM
10 GENERAL DESCRIPTION
11 HYDRAULIC SYSTEM SYMBOL LEGEND
FUNCTIONAL HYDRAULIC DIAGRAM
HYDRAULIC SYSTEM COMPONENTS
1

2 TABLE OF HYDRAULIC SYSTEM COMPONENTS
13 FLOW CONTROL AND HOSE BREAK VALVES
14 COMPONENT ACTUATION TABLE: PUMPS AND ELECTRO-SOLENOIDS
141 HYDRAULIC SYSTEM FUNCTIONAL LAYOUT
21 MAIN HYDRAULIC VALVE ASSEMBLY
2

10 MAIN HYDRAULIC VALVE ASSEMBLY COMPONENTS
22 CAB LIFT PRESSURE RELIEFVALVE ADJUSTMENT
23 ADJUSTING THE CAB LOWER PROPORTIONAL VALVE
231 EMERGENCY LOWER SCREW
24 TROUBLE-SHOOTING
31 AUXILIARY MAST/ATTACHMENT VALVE ASSEMBLY
3

10 AUXILIARY MAST/ATTACHMENT VALVE COMPONENT TABLE
32 AUXILIARY MAST/ATTACHMENT VALVE MAIN PRESSURE RELIEF ADJUSTMENT
33 ADJUSTING AUXILIARY MAST LOWER PROPORTIONAL VALVE
34 TROUBLE-SHOOTING
41 CAB LIFT CYLINDER EXPLODED DRAWING V30XMU C1

0 C13 (2 STAGE MAST)
42 CAB LIFT CYLINDER TABLE OF COMPONENTS FOR V30XMU C10 C13
51 CAB LIFT CYLINDER EXPLODED DRAWING V30XMU C10 C13 (3 STAGE MAST)
52 CAB LIFT CYLINDER TABLE OF COMPONENTS FOR V30XMU C1

0 C13
61 CAB LIFT CYLINDER EXPLODED DRAWING V35XMU V40XMU C15B C18X (2 STAGE MAST)
62 CAB LIFT CYLINDER TABLE OF COMPONENTS FOR V35XMU V40XMU C15B C18X
71 CAB LIFT CYLINDER EXPLODED DRAWING V35XMU V40XMU C1

5B C18X (3 STAGE MAST)
72 CAB LIFT CYLINDER TABLE OF COMPONENTS FOR V35XMU V40XMU C15B C18X
81 DISSASSEMBLING THE MAIN LIFT CYLINDERS
82 CHANGING THE SEALS
83 INSTALLING THE MAIN LIFT CYLINDERS ON THE MACHINE
8

4 BLEEDING THE AIR FROM THE MAIN HOIST CYLINDER
91 AUXILIARY MAST LIFT CYLINDER EXPLODED DRAWING
92 AUXILIARY MAST LIFT CYLINDER PART TABLE FOR
101 DISMANTLING AUXILIARY MAST LIFT CYLINDER
102 CHANGING THE SEALS
10

3 REASSEMBLING THE AUXILIARY MAST LIFT CYLINDER
104 BLEEDING THE AIR FROM THE AUXILIARY MAST LIFT CYLINDER

Section: ATTACHMENT
11 ATTACHMENT COMPONENTS
12 ATTACHMENT COMPONENT TABLE
21 TRILATERAL ATTACHMENT FUNCTIONING
3

1 TRUCK INSTALLATION
311 ATTACHMENT ASSEMBLY PROCEDURES
41 MECHANIC ADJUSTMENT OF THE ATTACHMENT SUPPORT BEARINGS
51 MECHANIC STROKE END ADJUSTMENT
52 ROTATING MECHANIC STROKE END AND CAMS
53 TRASLATION SPEED REDUCER MICROSWITCH
6

1 MECHANICAL ADJUSTMENTS OF THE LOAD HANDLER BEARINGS
71 MAINTENANCE
81 TROUBLESHOOTING

Section: MAST
11 REMOVING THE CAB FROM THE MAST
10 MAST REMOVAL PROCEDURE MOD EU C10 C13 C15B C18X MOD

US V30XMU V35XMU V40XMU
20 REMOVING THE CYLINDERS MOD EU C10 C13 C15B MOD US V30XMU V35XMU
21 REMOVING THE MAST MOD EU C10 C13 C15B MOD US V30XMU V35XMU
30 REMOVING THE BOTTOM GUIDE BEARING OF THE INNER MAST SECTION MOD

EU C10 C13 MOD US V30XMU
40 REMOVING THE ROLLERS FROM THE CAB AND INNER TELESCOPING SECTION MOD EU C15B C18X MOD US V35XMU V40XMU 50 REMOVING SIDE ROLLERS FROM THE MAST MOD EU C15B C18X MOD US V35XMU V40XMU
Section: BILATERAL EQUIPMENT
1

0 DESCRIPTION OF EQUIPMENT
101 COMPOSITION
102 TELESCOPING ACTION
11 TOP TELESCOPING SECTION OR LOAD PLATFORM
12 INTERMEDIATE TELESCOPING SECTION
13 TELESCOPING SECTION SUPPORT
14 TELESCOPING ASSEMBLY
1

5 TABLE OF COMPONENTS
20 MAINTENANCE
201 HOW TO DISMANTLE THE EQUIPMENT
202 TIGHTENING TORQUES
203 PRECAUTIONS WHEN USING MAINTENANCE PRODUCTS
204 COMPONENTS REQUIRING MAINTENANCE
205 ROUTINE MAINTENANCE OPERATIONS
2

06 ITEMS NOT REQUIRING RELUBRICATION
207 SYMBOLS
208 FAULT-FINDING AND REMEDIES
30 REMOVING THE VARIOUS SECTORS
40 DISASSEMBLING EQUIPMENT
50 REMOVAL PROCEDURE
Section: WHEELS
10 REMOVING THE LOAD WHEELS
2

0 REMOVING THE DRIVE WHEELS MOD US V30XMU V35XMU EU C10 (EU ONLY) C13 C15B
30 REMOVING THE DRIVE WHEELS MOD US V40XMU EU C18X

Section: BRAKING SYSTEM
10 BRAKING SYSTEMS DESCRIPTION
2

0 REMOVAL AND ADJUSTMENT OF THE ELECTROMAGNETIC BRAKE
30 ADJUSTMENT AND PUTTING INTO SERVICE
Section: TRANSMISSION
11 DISMANTLING THE TRANSMISSION FROM THE TRUCK US V30XMU V35XMU EU C10 (EU ONLY) C1

3 C15B
12 INTRODUCTION
13 DISMANTLING THE CONNECTIONS
14 CHAIN
15 REMOVING THE TRANSMISSION UNIT
16 TRANSMISSION OIL
17 REMOVING THE MOTOR
17A REMOVING THE PLATE
18 DISMANTLING THE CHAIN
1

9 DISMANTLING THE WHEEL
20 DISMANTLING THE TRANSMISSION FROM THE TRUCK MOD V40XMU C18X
30 GENERAL INFORMATION V30XMU V35XMU C10 C13 C15B
31 TRANSMISSION COMPONENTS
32 CONSUMABLE GOODS
3

4 STANDARD TOOLS AND FIXTURES
40 DISASSEMBLY
41 INTRODUCTION
42 REMOVAL AND DISASSEMBLY OF THE TRANSMISSION HOUSING UPPER PART
43 REMOVING OF THE TRANSMISSION COVER
44 DISMANTLING THE CROWN GEAR AND WHEEL SHAFT
4

5 REMOVING THE TAPER ROLLER BEARING INNER RACE FROM THE WHEEL SHAFT AND CROWN GEAR
46 DISASSEMBLY OF THE PINION SHAFT
47 DISASSEMBLY OF THE TAPER ROLLER BEARING OUTER RACE FROM THE TRANSMISSION HOUSING
48 REMOVING THE THREAD PROTECTIVE SHIELD
5

0 ASSEMBLY
51 INTRODUCTION
52 MEASURING THE ASSEMBLY DIMENSION OF THE PINION SHAFT
53 PRE-ASSEMBLY OF THE TRANSMISSION HOUSING
54 PRE-ASSEMBLY OF THE WHEEL SHAFT
55 MOUNTING THE TAPER ROLLER BEARING INNER RACE ON THE CROWN GEAR
5

6 PRE-ASSEMBLY OF THE PINION SHAFT
57 MOUNTING THE PINION SHAFT IN THE TRANSMISSION HOUSING
58 MEASURING THE BEARING CLEARANCE OF THE PINION SHAFT AND ADJUSTING THE PRE-STRESS
59 MOUNTING THE WHEEL SHAFT AND THE CROWN GEAR ON THE TRANSMISSION HOUSING
5

10 MEASURING AND ADJUSTING THE CROWN GEAR CIRCUMFERENTIAL BACKLASH
511 CHECKING THE TOOTH PATTERN
512 MEASURING THE WHEEL SHAFT BEARING CLEARANCE AND ADJUSTING THE BEARING PRE-STRESS
513 MOUNTING THE THREAD PROTECTIVE SHIELD IN THE TRANSMISSION HOUSING
5

14 MOUNTING THE RADIAL SHAFT SEAL IN THE TRANSMISSION HOUSING
515 MOUNTING THE HOUSING COVER
516 TRANSMISSION UPPER PART
60 ADJUSTMENT DATA
61 TIGHTENING TORQUE
70 TROUBLESHOOTING
80 STORAGE
81 DECOMMISSIONING

Guide Wire Installation

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

DC-EPS POWER STEERING AND WIRE GUIDANCE

Electrical Drawings (C1

5B)

Electrical Drawings (V40XMU)

Hydraulic Diagram Electrical Diagrams

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

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