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Hyster A20XL, A25XL, A30XL service manual – PDF DOWNLOAD
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Description
Hyster A20XL, A25XL, A30XL service manual
File Details:
Hyster A20XL, A25XL, A30XL service manual
Language : English
Pages : 313
Size : 7.99 MB
Downloadable : Yes
Format : PDF
HYSTER A20XL, A25XL, A30XL SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster A20XL, A25XL, A30XL service manual
- This hyster parts covers all parts information you need.It 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 drawings.Keep 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.
Table of Contents:
Hyster A20XL, A25XL, A30XL service manual
INTRODUCTION....................................................................................................................... 1 GENERAL........................................................................................................................ 1 INDICATORS WITH METER MOVEMENTS................................................................................................ 2 BATTERY INDICATORS WITH LCD OR LED DISPLAYS.................................................................................... 3 Liquid Crystal Displays.................................................................................................... 3 Light Emitting Diode Displays.............................................................................................. 7 CHECKS AND ADJUSTMENTS............................................................................................................. 9 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS........................................................................ 9 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS........................................................................... 9 Reset Potentiometer........................................................................................................ 9 Specific Gravity Alarm..................................................................................................... 10 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS........................................................................ 11 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS........................................................................... 11 Reset Potentiometer........................................................................................................ 11 Discharge Potentiometer.................................................................................................... 11 LED DISPLAY WITH LIFT INTERRUPT................................................................................................ 12 CHECKING CURTIS 933-1 METER.................................................................................................... 12 Reset Check................................................................................................................ 12 Discharge Check............................................................................................................ 13 Lockout Check.............................................................................................................. 13 LED's Do Not Illuminate.................................................................................................... 14 Hourmeter Check............................................................................................................ 14 Hour Glass Icon............................................................................................................ 14 ADJUSTMENT OF CURTIS 933-1 METER........................................................................................... 14 CHECKING CURTIS 1215 BATTERY INDICATOR..................................................................................... 14 ADJUSTING CURTIS 1215 BATTERY INDICATOR.................................................................................... 15 Voltage Selection...................................................................................................... 16 ADJUSTING BDI OF SEM DISPLAY PANEL......................................................................................... 17 REPAIRS........................................................................................................................ 17 BATTERY INDICATORS......................................................................................................... 17 Replacement............................................................................................................ 17 CONTROLLER FOR THE BATTERY INDICATOR....................................................................................... 17 Replacement............................................................................................................ 17 DISPLAY PANEL COMPONENTS................................................................................................... 17 REPLACING SEM DISPLAY PANEL................................................................................................ 17 SEM Display Panel REMOVAL.................................................................................................. 19 Removal And Replacement................................................................................................ 19 INTRODUCTION....................................................................................................................... 21 GENERAL........................................................................................................................ 21 DESCRIPTION AND OPERATION...................................................................................................... 21 REPAIRS............................................................................................................................ 23 MASTER CYLINDER, EARLY MODELS.................................................................................................. 23 Removal And Disassembly.................................................................................................... 23 Cleaning And Inspection.................................................................................................... 24 Assembly And Installation.................................................................................................. 24 MASTER CYLINDER, LATE MODELS................................................................................................... 25 Removal And Disassembly.................................................................................................... 25 Cleaning And Inspection.................................................................................................... 25 Assembly and Installation.................................................................................................. 25 SERVICE AND PARKING BRAKES..................................................................................................... 26 Removal And Disassembly.................................................................................................... 26 Cleaning................................................................................................................... 26 Inspection................................................................................................................. 27 Assembly And Installation.................................................................................................. 27 CHECKS AND ADJUSTMENTS............................................................................................................. 29 REMOVE THE AIR FROM THE BRAKE SYSTEM........................................................................................... 29 ADJUST THE SERVICE BRAKES...................................................................................................... 29 ADJUST THE BRAKE PEDAL, EARLY MODELS........................................................................................... 29 ADJUST THE BRAKE PEDAL, LATE MODELS............................................................................................ 30 ADJUST THE PARKING BRAKE....................................................................................................... 30 TROUBLESHOOTING.................................................................................................................... 31 INTRODUCTION....................................................................................................................... 38 ELECTRIC MOTOR MAINTENANCE, GENERAL............................................................................................ 38 BRUSH AND COMMUNICATOR INSPECTION.............................................................................................. 38 Hydraulic Pump Motor And Traction Motor.................................................................................... 38 Steering Pump Motor........................................................................................................ 40 BRUSH WEAR REPLACEMENT GUIDE....................................................................................................... 40 Commutator Problems............................................................................................................ 42 BRUSH REPLACEMENTS............................................................................................................. 44 DISASSEMBLY OF MOTORS.......................................................................................................... 46 Traction Motor And Hydraulic Pump Motor.................................................................................... 46 Steering Pump Motor........................................................................................................ 52 ASSEMBLY OF MOTORS............................................................................................................. 54 Traction Motor And Hydraulic Pump Motor ................................................................................... 54 Steering Pump Motor........................................................................................................ 54 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS................................................................................. 54 TESTS FOR A DAMAGED FIELD AND ARMATURE......................................................................................... 55 Test For An Open Circuit In The Armature................................................................................... 55 Test For A Short-Circuit In One Armature Winding........................................................................... 55 Test For A Short-Circuit To Armature Shaft................................................................................. 56 Test For An Open Circuit In A Field Coil................................................................................... 56 Test For A Short-Circuit In A Field Coil................................................................................... 56 Test For A Short-Circuit Between The Field And The Motor Case.............................................................. 57 Brush Holder Test.......................................................................................................... 57 TROUBLESHOOTING.................................................................................................................... 57 INTRODUCTION....................................................................................................................... 65 GENERAL........................................................................................................................ 65 DESCRIPTION.................................................................................................................... 65 REPAIRS............................................................................................................................ 66 OVERHEAD GUARD................................................................................................................. 66 Removal.................................................................................................................... 66 Installation............................................................................................................... 66 HOOD AND SEAT ASSEMBLY......................................................................................................... 66 Removal.................................................................................................................... 68 COUNTERWEIGHT.................................................................................................................. 68 Removal.................................................................................................................... 68 Installation............................................................................................................... 69 HYDRAULIC TANK................................................................................................................. 69 Inspection................................................................................................................. 69 Repairs, Small Leaks....................................................................................................... 69 Cleaning................................................................................................................... 69 SAFETY LABELS.................................................................................................................. 70 BATTERY SPECIFICATIONS............................................................................................................. 72 INTRODUCTION....................................................................................................................... 73 GENERAL........................................................................................................................ 73 DESCRIPTION.................................................................................................................... 73 CONTROL VALVE...................................................................................................................... 76 DESCRIPTION.................................................................................................................... 76 OPERATION...................................................................................................................... 76 Lift Section............................................................................................................... 77 Tilt Section............................................................................................................... 78 Relief Valve............................................................................................................... 81 Check Valves, Description.................................................................................................. 82 Check Valves, Cleaning And Inspection...................................................................................... 82 REPAIRS........................................................................................................................ 83 Removal.................................................................................................................... 83 Disassembly................................................................................................................ 83 Cleaning and Inspection.................................................................................................... 84 Assembly................................................................................................................... 84 Installation............................................................................................................... 84 CHECKS AND ADJUSTMENTS......................................................................................................... 84 Relief Valve Adjustment.................................................................................................... 84 Control Levers, Linkage and Switches....................................................................................... 86 HYDRAULIC PUMP..................................................................................................................... 86 DESCRIPTION.................................................................................................................... 86 REPAIRS........................................................................................................................ 86 Removal.................................................................................................................... 87 Seal Replacement........................................................................................................... 87 Installation............................................................................................................... 88 TROUBLESHOOTING (HYDRAULIC PUMP)................................................................................................... 89 TROUBLESHOOTING (CONTROL VALVE).................................................................................................... 90 SPECIFICATIONS..................................................................................................................... 91 INTRODUCTION....................................................................................................................... 93 GENERAL........................................................................................................................ 93 LEAD-ACID BATTERIES............................................................................................................ 93 SPECIFIC GRAVITY............................................................................................................... 94 CHEMICAL REACTION IN A CELL.................................................................................................... 94 ELECTRICAL TERMS............................................................................................................... 95 HOW TO SELECT THE BATTERY...................................................................................................... 95 VOLTAGE OF A BATTERY........................................................................................................... 95 THE BATTERY AS A COUNTERWEIGHT................................................................................................. 96 BATTERY RATINGS................................................................................................................ 96 Kilowatt-Hours............................................................................................................. 97 BATTERY MAINTENANCE................................................................................................................ 97 SAFETY PROCEDURES.............................................................................................................. 97 MAINTENCE RECORDS.............................................................................................................. 98 THE NEW BATTERY................................................................................................................ 98 HOW TO CLEAN THE BATTERY....................................................................................................... 99 HOW TO ADD WATER............................................................................................................... 99 THE HYDROMETER.................................................................................................................100 BATTERY TEMPERATURE............................................................................................................100 CHARGING THE BATTERY...........................................................................................................101 Types Of Battery Charges...................................................................................................102 Methods Of Charging........................................................................................................103 Troubleshooting The Charger................................................................................................103 How to Know When The Battery Is Fully Charged..............................................................................104 WHERE TO CHARGE THE BATTERIES..................................................................................................104 Equipment Needed...........................................................................................................104 BATTERY CONNECTORS.............................................................................................................105 BATTERY CARE...................................................................................................................105 INTRODUCTION.......................................................................................................................107 GENERAL........................................................................................................................107 DESCRIPTION....................................................................................................................107 REPAIR.............................................................................................................................109 REMOVAL........................................................................................................................109 Mount Type A...............................................................................................................109 Mount Type B (A20-30XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)..................................................109 Mount Type B (R30DH Only)..................................................................................................110 DISASSEMBLY....................................................................................................................110 ASSEMBLY.......................................................................................................................112 General....................................................................................................................112 Installing The Spiral Bevel Pinion.........................................................................................114 Installing The Spiral Bevel Gear...........................................................................................115 INSTALLATION...................................................................................................................117 Mount Type A...............................................................................................................117 Mount Type B (A20-30XL, N40-50EA/ER, N50FA, N30-45FR, R30E/EA/EF/ES Only)..................................................117 Mount Type B (R30DH Only)..................................................................................................118 CHECKS AND ADJUSTMENTS.............................................................................................................119 ADJUST BACKLASH AND TOOTH CONTACT..............................................................................................119 ADJUST BEARING CLEARANCE.......................................................................................................120 TROUBLESHOOTING....................................................................................................................121 INTRODUCTION.......................................................................................................................124 General........................................................................................................................124 REPAIRS............................................................................................................................124 Removal........................................................................................................................124 Disassembly....................................................................................................................126 Assembly.......................................................................................................................127 Installation...................................................................................................................129 CHECKS AND ADJUSTMENTS.............................................................................................................130 Check The Operation And Alignment Of The Steering System.......................................................................130 Pinion And Gear Clearance......................................................................................................131 Adjusting Pinion And Gear Clearances.......................................................................................131 Adjustment For Correct Contact Pattern Of Gear Teeth.......................................................................132 TROUBLESHOOTING....................................................................................................................134 INTRODUCTION.......................................................................................................................137 GENERAL........................................................................................................................137 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...................................................................................137 HOW TO MOVE A DISABLED LIFT TRUCK..............................................................................................139 How To Tow A Lift Truck........................................................................................................139 HOW TO PUT A LIFT TRUCK ONTO BLOCK.............................................................................................139 How To Raise The Load Wheels...................................................................................................139 How To Raise The Steer Wheels..................................................................................................140 MAINTENANCE SCHEDULE...............................................................................................................140 TABLE 1. MAINTENANCE SCHEDULE......................................................................................................141 MAINTENANCE PROCEDURES.............................................................................................................142 EVERY 8 HOURS OR DAILY.............................................................................................................142 CHECKS BEFORE OPERATION........................................................................................................142 Hydraulic System...........................................................................................................142 Battery....................................................................................................................142 Operator Restraint System..................................................................................................143 Battery Restraint System...................................................................................................143 Mast, Forks and, Lift Chains...............................................................................................144 Lift Chain Adjustments.....................................................................................................145 Tires and Wheels...........................................................................................................146 CHECK THE OPERATION............................................................................................................146 Gauges and Horn............................................................................................................146 Control Levers and Panels..................................................................................................147 Lift System and Operation..................................................................................................147 Service Brakes.............................................................................................................147 Parking Brake..............................................................................................................147 Steering System............................................................................................................147 EVERY 350 HOURS OR TWO MONTHS......................................................................................................148 HYDRAULIC TANK BREATHER........................................................................................................148 WHEEL NUT TORQUES..............................................................................................................148 MDU (SPETH)....................................................................................................................148 MDU (HURTH)....................................................................................................................148 MAST...........................................................................................................................149 LIFT CHAINS....................................................................................................................149 FORKS..........................................................................................................................150 SAFETY LABELS..................................................................................................................150 BRAKE FLUID....................................................................................................................150 OTHER LUBRICATION..............................................................................................................150 ELECTRICAL INSPECTION..........................................................................................................150 Contactors.................................................................................................................150 Motor Brushes..............................................................................................................150 2000 HOURS OR YEARLY...............................................................................................................151 HYDRAULIC SYSTEM...............................................................................................................151 Change the Hydraulic Oil Filter............................................................................................151 Change the Hydraulic Oil...................................................................................................151 BRAKE SHOES....................................................................................................................151 STEERING SYSTEM................................................................................................................151 MDU (SPETH)....................................................................................................................151 MDU (HURTH)....................................................................................................................151 ADJUST THE SERVICE BRAKES......................................................................................................152 ADJUST THE PARKING BRAKE.......................................................................................................152 GENERAL PROCEDURES.................................................................................................................153 CHECK FOR LEAKS IN THE LIFT SYSTEM AND TILT SYSTEM.............................................................................153 Lift System....................................................................................................................153 Tilt System....................................................................................................................153 HOW TO CHARGE THE BATTERY......................................................................................................153 TABLE 2. CHECK SPECIFIC GRAVITY....................................................................................................154 HOW TO CHANGE THE BATTERY......................................................................................................154 WHEELS AND TIRES...................................................................................................................155 GENERAL........................................................................................................................155 HOW TO CHANGE THE TIRES........................................................................................................155 General....................................................................................................................155 Solid Rubber Tires (Press-on)..............................................................................................156 Pneumatic Tires............................................................................................................156 REMOVE THE WHEELS FROM THE LIFT TRUCK..........................................................................................156 REMOVE THE WHEEL FROM THE TIRE.................................................................................................156 INSTALL THE WHEEL IN THE TIRE..................................................................................................157 ADD AIR TO THE TIRES...........................................................................................................158 INSTALL THE WHEELS.............................................................................................................158 BATTERY SIZE SPECIFICATIONS........................................................................................................159 INTRODUCTION.......................................................................................................................160 NOMENCLATURE, THREADS..........................................................................................................160 STRENGTH IDENTIFICATION........................................................................................................161 TABLE 1. BOLTS AND SCREWS..........................................................................................................161 TABLE 2. STUDS AND NUTS............................................................................................................162 TABLE 3. TORQUE NUTS...............................................................................................................163 TABLE 4. TORQUE NUTS WITH NYLON INSERT.............................................................................................164 TABLE 5. TORQUE VALUES FOR INCH FASTENERS..........................................................................................165 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS........................................................................................166 INTRODUCTION.......................................................................................................................169 GENERAL........................................................................................................................169 FUSES..........................................................................................................................170 THE LOGIC BOX..................................................................................................................170 TABLE 1. PIN ARRANGEMENT AND FUNCTIONS FOR THE LOGIC BOX PLUG..................................................................171 ADJUSTMENTS....................................................................................................................173 Acceleration Delay (P1)....................................................................................................173 1A By-Pass (P4)........................................................................................................173 Current Limit (P3).....................................................................................................173 1A Dropout (P5)........................................................................................................174 Plugging (P2)..........................................................................................................175 REPAIRS............................................................................................................................175 CHECK THE SCRs.................................................................................................................175 Check SCR 1................................................................................................................175 Replacement Of SCR 1.......................................................................................................177 Check SCR 2 and SCR 5......................................................................................................178 Replacement of SCR 2 and SCR 5.............................................................................................178 Check The Diodes D3 And D4.................................................................................................179 Replacement Of A Diode.....................................................................................................179 THE LC CIRCUIT.................................................................................................................179 Check the Inductor L1 Coil.................................................................................................179 Replacement Of The L1 Coil.................................................................................................179 Check Capacitor C1.........................................................................................................179 Capacitor C1 Replacement...................................................................................................180 Check The Thermal Switch...................................................................................................181 Replacement Of The Thermal Switch..........................................................................................181 CONTACTORS.....................................................................................................................181 CONTACTORS REPAIR..............................................................................................................183 Removing A Contactor Assembly..............................................................................................183 Contactor Contacts.........................................................................................................183 Coil.......................................................................................................................183 CONTROL SWITCHES...............................................................................................................183 Key Switch.................................................................................................................184 Seat Switch................................................................................................................184 Start Switch...............................................................................................................184 Direction Switch (Steering Column).........................................................................................184 Direction Switch (MONOTROL)................................................................................................184 Pedal Adjustment...........................................................................................................185 Accelerator Circuit........................................................................................................185 TORQUE SPECIFICATIONS..............................................................................................................187 INTRODUCTION.......................................................................................................................188 GENERAL........................................................................................................................188 LIFT TRUCK CONTROL.............................................................................................................188 PRINCIPLES OF OPERATION............................................................................................................190 The Silicon Controlled Rectifier (SCR).........................................................................................190 A Motor Circuit That Operates With Pulses..................................................................................191 The SCR 1 "OFF" Circuit....................................................................................................191 INDUCTION CURRENT FROM THE MOTOR...........................................................................................193 THE LOGIC BOX (Traction Circuit)...........................................................................................194 TABLE 1. PIN ARRANGEMENT AND FUNCTION FOR THE LOGIC BOX PLUG.......................................................................195 TABLE 1. PIN ARRANGEMENT AND FUNCTION FOR THE LOGIC BOX PLUG...................................................................195 SRO Circuit (See FIGURE 10.) ..............................................................................................197 Fault Sensor...............................................................................................................197 Other Functions of the Logic Box...........................................................................................197 1A BY-PASS CIRCUIT.........................................................................................................197 "PLUGGING".................................................................................................................198 VOLTAGE CONTROL MODULE.....................................................................................................198 "RAMP START"...............................................................................................................199 CONTACTORS.....................................................................................................................199 CIRCUIT PROTECTION.............................................................................................................200 Thermal Protection.........................................................................................................200 Current Limit .............................................................................................................200 Fuses......................................................................................................................200 SEQUENCE OF OPERATION..........................................................................................................200 INTRODUCTION.......................................................................................................................207 General........................................................................................................................207 SRO CIRCUIT AND FAULT SENSOR.......................................................................................................209 "Static Return To Off" (Sro) Circuit...........................................................................................209 Fault Sensor...................................................................................................................209 Checking For The Correct Operation.............................................................................................209 TROUBLESHOOTING....................................................................................................................210 General Procedures.............................................................................................................210 Fault Number 1. The Direction Contactors Will Not Close For Operation In Either Direction......................................211 Fault Number 2. The Lift Truck Will Not Move In Either Direction. The Direction Contactors Close And Then Immediately Open.....214 Fault Number 3. The Lift Truck Will Not Move In Either Direction. The Direction Contactor Closes Normally And Then Opens.......215 Fault Number 4. The Lift Truck Will Not Move In Either Direction. Both Direction Contactors Close..............................216 Fault Number 5. One Direction Contactors Will Not Close. The Traction Circuit Operates Normally In Only One Direction..........217 Fault Number 6. Contactor 1a Will Not Energize. The Other Operations Of The Lift Truck Are Normal..............................218 Fault Number 7. Plugging Problems..............................................................................................219 Fault Number 8. Hydraulic Control Problems.....................................................................................219 Table 1. Pin Arrangement And Functions For The Logic Box Plug......................................................................220 INTRODUCTION.......................................................................................................................222 GENERAL........................................................................................................................222 DESCRIPTION....................................................................................................................222 OPERATION......................................................................................................................222 REPAIRS............................................................................................................................222 STEERING WHEEL AND COLUMN ASSEMBLY.............................................................................................222 TYPE "A" STEERING COLUMN ASSEMBLY..............................................................................................224 Removal And Disassembly....................................................................................................224 Assembly And Installation..................................................................................................224 TYPE "A" STEERING COLUMN.......................................................................................................225 TYPE "A" STEERING COLUMN.......................................................................................................226 TYPE "B" STEERING COLUMN.......................................................................................................227 Removal And Disassembly....................................................................................................227 Assembly And Installation..................................................................................................227 TYPE "B" STEERING COLUMN.......................................................................................................228 Disassembly of Steering Control Unit.......................................................................................229 Cleaning of Steering Control Unit..........................................................................................229 Assembly of Steering Control Unit..........................................................................................231 CHECKS AND ADJUSTMENTS.............................................................................................................234 REMOVE AIR FROM THE SYSTEM.....................................................................................................234 TROUBLESHOOTING....................................................................................................................235 STEERING SYSTEM....................................................................................................................236 GENERAL........................................................................................................................236 DESCRIPTION....................................................................................................................238 STEERING WHEEL AND COLUMN ASSEMBLY.............................................................................................239 Removal Of The Assembly Components.........................................................................................239 Installation Of The Assembly Components....................................................................................243 POWER STEERING MOTOR AND PUMP......................................................................................................244 DESCRIPTION....................................................................................................................244 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM).............................244 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)..................................................................244 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)...............................................................................245 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)..............................................................................247 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS).............................................................................248 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)].................................248 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM).............................................................................249 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)...........................................................................251 REPAIRS, POWER STEERING PUMP...................................................................................................252 Seal Replacement...........................................................................................................253 HYDRAULIC STEERING MOTOR...........................................................................................................253 DESCRIPTION....................................................................................................................253 REPAIRS, HYDRAULIC STEERING MOTOR..............................................................................................254 Removal ...................................................................................................................254 Disassembly................................................................................................................254 Cleaning And Inspection....................................................................................................254 Assembly...................................................................................................................255 Installation, Hydraulic Steering Motor.....................................................................................256 CHECKS AND ADJUSTMENTS.............................................................................................................256 AIR IN THE STEERING SYSTEM.....................................................................................................256 CHECK STEERING PRESSURE........................................................................................................256 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)..................................................................257 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS..................................................................................258 TROUBLESHOOTING....................................................................................................................260 INTRODUCTION.......................................................................................................................263 GENERAL........................................................................................................................263 DESCRIPTION....................................................................................................................263 STEERING WHEEL AND COLUMN ASSEMBLY.............................................................................................264 REPAIR.............................................................................................................................267 REMOVAL, STEERING CONTROL UNIT.................................................................................................267 INSTALLATION, STEERING CONTROL UNIT............................................................................................267 POWER STEERING MOTOR AND PUMP......................................................................................................268 DESCRIPTION....................................................................................................................268 REMOVAL AND DISASSEMBLY........................................................................................................268 ASSEMBLY AND INSTALLATION......................................................................................................268 REPAIRS, POWER STEERING PUMP...................................................................................................270 SEAL REPLACEMENT...............................................................................................................271 HYDRAULIC STEERING MOTOR...........................................................................................................272 DESCRIPTION....................................................................................................................272 REPAIRS, HYDRAULIC STEERING MOTOR..............................................................................................272 Removal....................................................................................................................272 Disassembly................................................................................................................273 Cleaning And Inspection....................................................................................................273 Assembly...................................................................................................................273 Installation, Hydraulic Steering Motor.....................................................................................275 CHECKS AND ADJUSTMENTS.............................................................................................................275 POWER STEERING ADJUSTMENTS.....................................................................................................275 Air In The Steering System.................................................................................................275 Steering Pressure..........................................................................................................275 Check the Operation and Alignment of the Steering System...................................................................276 TROUBLESHOOTING....................................................................................................................276 INTRODUCTION.......................................................................................................................277 GENERAL........................................................................................................................277 MAST WELDMENTS.................................................................................................................277 CARRIAGE.......................................................................................................................277 MAST MOUNTS....................................................................................................................278 VISTA® TWO-STAGE MAST..............................................................................................................279 DESCRIPTION AND OPERATION......................................................................................................279 VISTA® FREE-LIFT MAST..............................................................................................................281 DESCRIPTION....................................................................................................................281 OPERATION......................................................................................................................281 VISTA® THREE-STAGE MAST............................................................................................................283 DESCRIPTION....................................................................................................................283 OPERATION......................................................................................................................283 VISTA® FOUR-STAGE MAST.............................................................................................................284 DESCRIPTION....................................................................................................................284 OPERATION......................................................................................................................285 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.......................................................................................287 INTRODUCTION.......................................................................................................................288 GENERAL........................................................................................................................288 FORKS..........................................................................................................................288 CARRIAGE.......................................................................................................................289 Removal....................................................................................................................289 Installation...............................................................................................................289 MAST...............................................................................................................................290 REMOVAL FROM THE LIFT TRUCK....................................................................................................290 DISASSEMBLY....................................................................................................................291 Two-Stage And Free-Lift Masts..............................................................................................291 Three-Stage Mast...........................................................................................................292 CLEANING AND INSPECTION........................................................................................................294 ASSEMBLY.......................................................................................................................295 Two-Stage And Free-Lift Mast...............................................................................................295 Two-Stage Mast.............................................................................................................296 Free-Lift Mast.............................................................................................................296 Three-Stage Mast...........................................................................................................296 INSTALLATION...................................................................................................................297 LIFT CYLINDERS.....................................................................................................................298 DESCRIPTION....................................................................................................................298 LOWERING CONTROL VALVE.........................................................................................................300 REMOVAL OF THE LIFT CYLINDERS WITHOUT REMOVING THE MAST........................................................................301 DISASSEMBLY....................................................................................................................302 Main Lift Cylinders........................................................................................................302 Free-lift Cylinder.........................................................................................................302 ASSEMBLY.......................................................................................................................302 Main Lift Cylinders........................................................................................................302 Free-Lift Cylinders........................................................................................................302 INSTALLATION OF THE LIFT CYLINDERS INTO THE MASTS..............................................................................303 Main Lift Cylinders........................................................................................................303 Free-Lift Cylinder.........................................................................................................303 TILT CYLINDER..................................................................................................................303 DESCRIPTION....................................................................................................................303 REMOVAL........................................................................................................................304 DISASSEMBLY....................................................................................................................304 CLEANING.......................................................................................................................304 ASSEMBLY.......................................................................................................................304 INSTALLATION...................................................................................................................304 SIDE-SHIFT CARRIAGE............................................................................................................305 Removal....................................................................................................................305 Removal....................................................................................................................305 Repairs....................................................................................................................305 Installation...............................................................................................................306 CHECKS AND ADJUSTMENTS.............................................................................................................308 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM....................................................................................308 Check The Lift Cylinder For Leaks..........................................................................................308 Check The Tilt Cylinder For Leaks..........................................................................................309 ADJUSTMENT OF THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.............................................................309 LIFT CHAIN ADJUSTMENTS.........................................................................................................309 MAST ADJUSTMENTS...............................................................................................................310 CARRIAGE ADJUSTMENT............................................................................................................312 SIDE-SHIFT CYLINDER ADJUSTMENT.................................................................................................312
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
