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Hyster B114 (E20-25B, E30BS) Service Manual – PDF DOWNLOAD
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Description
Hyster B114 (E20-25B, E30BS) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster B114 (E20-25B, E30BS) Service Manual – PDF DOWNLOAD
Language : English
Pages : 842
Downloadable : Yes
File Type : PDF
Size: 23.3 MB
TABLE OF CONTENTS:
Hyster B114 (E20-25B, E30BS) Service Manual – PDF DOWNLOAD
Binder1.......................................................................................................... 1 10027........................................................................................................ 1 INTRODUCTION............................................................................................. 1 GENERAL.............................................................................................. 1 DESCRIPTION.......................................................................................... 1 DISASSEMBLY AND ASSEMBLY................................................................................. 2 OVERHEAD GUARD....................................................................................... 2 Removal.......................................................................................... 2 Installation..................................................................................... 2 SEAT ASSEMBLY........................................................................................ 2 COUNTERWEIGHT........................................................................................ 2 Removal.......................................................................................... 3 Installation..................................................................................... 3 HYDRAULIC TANK REPAIRS............................................................................... 3 Small Leaks...................................................................................... 3 Large Leaks...................................................................................... 4 Steam Method Of Cleaning......................................................................... 4 Chemical Solution Method of Cleaning............................................................. 4 Other Methods.................................................................................... 4 LABEL REPLACEMENT.................................................................................... 5 22401........................................................................................................ 7 INTRODUCTION............................................................................................. 7 GENERAL.............................................................................................. 7 LEAD-ACID BATTERIES.................................................................................. 7 SPECIFIC GRAVITY..................................................................................... 7 THE CHEMICAL REACTION IN A CELL...................................................................... 8 ELECTRICAL TERMS......................................................................................... 9 HOW TO SELECT THE BATTERY............................................................................ 9 VOLTAGE OF A BATTERY................................................................................. 9 THE BATTERY AS A COUNTERWEIGHT....................................................................... 10 BATTERY RATINGS...................................................................................... 10 Kilowatt-Hours................................................................................... 11 BATTERY MAINTENANCE...................................................................................... 11 SAFETY PROCEDURES.................................................................................... 11 MAINTENACE RECORDS................................................................................... 12 THE NEW BATTERY...................................................................................... 12 HOW TO CLEAN THE BATTERY............................................................................. 13 HOW TO ADD WATER..................................................................................... 13 THE HYDROMETER....................................................................................... 14 BATTERY TEMPERATURE.................................................................................. 14 CHARGING THE BATTERY................................................................................. 15 Types Of Battery Charges......................................................................... 16 Methods Of Charging.............................................................................. 17 Troubleshooting The Charger...................................................................... 17 How To Know When The Battery Is Fully Charged.................................................... 18 WHERE TO CHARGE THE BATTERIES........................................................................ 18 Equipment Needed................................................................................. 18 BATTERY CONNECTORS................................................................................... 19 BATTERY CARE......................................................................................... 19 130062....................................................................................................... 21 INTRODUCTION............................................................................................. 21 General.............................................................................................. 21 Description.......................................................................................... 21 REPAIRS.................................................................................................. 22 Removal Of The Speed Reducer And Differential........................................................ 22 Disassembly.......................................................................................... 23 Assembly............................................................................................. 24 Installation Of The Drive Assembly................................................................... 28 TROUBLESHOOTING.......................................................................................... 28 160054....................................................................................................... 30 INTRODUCTION............................................................................................. 30 GENERAL.............................................................................................. 30 DESCRIPTION.......................................................................................... 30 OPERATION............................................................................................ 30 REPAIRS.................................................................................................. 30 STEERING WHEEL AND COLUMN ASSEMBLY................................................................... 30 TYPE "A" STEERING COLUMN ASSEMBLY.................................................................... 32 Removal And Disassembly.......................................................................... 32 Assembly And Installation........................................................................ 32 TYPE "A" STEERING COLUMN............................................................................. 33 TYPE "A" STEERING COLUMN............................................................................. 34 TYPE "B" STEERING COLUMN............................................................................. 35 Removal And Disassembly.......................................................................... 35 Assembly And Installation........................................................................ 35 TYPE "B" STEERING COLUMN............................................................................. 36 Disassembly of Steering Control Unit............................................................. 37 Cleaning of Steering Control Unit................................................................ 37 Assembly of Steering Control Unit................................................................ 39 CHECKS AND ADJUSTMENTS................................................................................... 42 REMOVE AIR FROM THE SYSTEM........................................................................... 42 TROUBLESHOOTING.......................................................................................... 43 180013....................................................................................................... 44 INTRODUCTION............................................................................................. 44 GENERAL.............................................................................................. 44 DESCRIPTION.......................................................................................... 44 REPAIRS.................................................................................................. 44 REMOVAL AND DISASSEMBLY.............................................................................. 44 CLEANING ............................................................................................ 45 ASSEMBLY............................................................................................. 45 CHECKS AND ADJUSTMENTS................................................................................... 45 CHECKS............................................................................................... 45 190097....................................................................................................... 46 INTRODUCTION............................................................................................. 46 DESCRIPTION.......................................................................................... 46 OPERATION............................................................................................ 46 Flow Control Valve............................................................................... 48 Relief Valve..................................................................................... 48 REPAIRS.................................................................................................. 49 REMOVAL.............................................................................................. 49 DISASSEMBLY.......................................................................................... 49 CLEANING............................................................................................. 51 INSPECTION........................................................................................... 51 ASSEMBLY............................................................................................. 52 INSTALLATION......................................................................................... 53 CHECKS AND ADUSTMENTS.................................................................................... 54 CHECK THE OUTPUT OF THE PUMP......................................................................... 54 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................ 54 TROUBLESHOOTING.......................................................................................... 56 190098....................................................................................................... 59 INTRODUCTION............................................................................................. 59 GENERAL.............................................................................................. 59 DESCRIPTION.......................................................................................... 59 OPERATION............................................................................................ 59 Pump............................................................................................. 59 Relief Valve..................................................................................... 60 REPAIRS.................................................................................................. 61 REMOVAL.............................................................................................. 61 DISASSEMBLY.......................................................................................... 61 ASSEMBLY............................................................................................. 62 INSTALLATION......................................................................................... 63 CHECKS AND ADJUSTMENTS................................................................................... 63 CHECKING THE RELIEF PRESSURE OF THE RELIEF VALVE..................................................... 63 Lift Trucks With Internal Combustion Engines..................................................... 63 Electric Lift Trucks............................................................................. 63 Electric Lift Trucks With Adjustable Relief Valve................................................ 64 SPECIFICATIONS........................................................................................... 65 TROUBLESHOOTING.......................................................................................... 65 620145....................................................................................................... 66 ......................................................................................................... 66 ......................................................................................................... 67 ......................................................................................................... 68 ......................................................................................................... 69 ......................................................................................................... 70 ......................................................................................................... 71 ......................................................................................................... 72 ......................................................................................................... 73 ......................................................................................................... 74 ......................................................................................................... 75 ......................................................................................................... 76 ......................................................................................................... 77 ......................................................................................................... 78 ......................................................................................................... 79 ......................................................................................................... 80 ......................................................................................................... 81 ......................................................................................................... 82 ......................................................................................................... 83 ......................................................................................................... 84 ......................................................................................................... 85 ......................................................................................................... 86 ......................................................................................................... 87 ......................................................................................................... 88 ......................................................................................................... 89 ......................................................................................................... 90 ......................................................................................................... 91 ......................................................................................................... 92 ......................................................................................................... 93 ......................................................................................................... 94 ......................................................................................................... 95 620294....................................................................................................... 96 toc...................................................................................................... 96 DC Motor Maintenance................................................................................. 96 Safety Precautions Maintenance and Repair............................................................ 97 General..............................................................................................100 Brush and Commutator Inspection......................................................................100 Hydraulic Pump Motor and Traction Motor..........................................................100 Steering Pump Motor..............................................................................103 Normal Commutator Surface........................................................................103 Commutator Problems..............................................................................103 Brush Replacement....................................................................................107 Stoning the Commutator...............................................................................109 Motors Repair........................................................................................111 Disassemble......................................................................................111 Traction Motor and Hydraulic Pump Motor......................................................111 Steering Pump Motor..........................................................................115 Assemble.........................................................................................115 Traction Motor and Hydraulic Pump Motor......................................................115 Steering Pump Motor..........................................................................116 Brush Alignment, Traction and Hydraulic Motors.......................................................119 Tests for Damaged Field and Armature.................................................................119 Test for an Open Circuit in Armature.............................................................119 Test for Short Circuit in One Armature Winding...................................................120 Test for Short Circuit to Armature Shaft.........................................................120 Test for Open Circuit in Field Coil..............................................................120 Test for Short Circuit in Field Coil.............................................................120 Test for Short Circuit between Field and Motor Case..............................................121 Brush Holder Test................................................................................121 Troubleshooting......................................................................................121 tables................................................................................................... 96 Table 1. Normal Commutator Surfaces..................................................................102 Table 2. Commutator Problems.........................................................................103 Table 3. Brush Wear Replacement Guide................................................................107 1400209......................................................................................................126 INTRODUCTION.............................................................................................126 General..............................................................................................126 Description..........................................................................................126 REPAIRS..................................................................................................126 Removal Of The Drive Axle (E20-30BS).................................................................126 Installation.........................................................................................128 Removal Of The Drive Axle (E20-30BH).................................................................128 Installation.........................................................................................129 Wheels And Tires.....................................................................................130 Removal Of The Speed Reducer And Differential........................................................131 Disassembly..........................................................................................134 Assembly.............................................................................................135 Installation Of The Drive Assembly...................................................................137 TROUBLESHOOTING..........................................................................................139 1600212......................................................................................................140 MANUAL STEERING SYSTEM (E20-30BS)........................................................................140 System Description...................................................................................141 Steering Wheel Assembly..............................................................................141 Steering Column Assembly.............................................................................142 Steering Gear Assembly...............................................................................144 Tie Rods And Drag Link...............................................................................150 Steering Axle Assembly...............................................................................151 Wheel Hubs And Spindles..............................................................................156 POWER STEERING SYSTEM....................................................................................159 System Description...................................................................................159 Steering Wheel And Column Assembly...................................................................160 Steering Control Unit................................................................................162 Power Steering Motor And Pump........................................................................162 Power Steering Axle Assembly.........................................................................163 Steering Cylinder....................................................................................164 Wheel Hubs And Spindles..............................................................................168 Inspection Requirements..............................................................................168 Manual Steering Checks And Adjustments...............................................................173 E20-30BH STEERING SYSTEM SUPPLEMENT......................................................................175 MANUAL STEERING SYSTEM...................................................................................175 Steering Axle Assembly...............................................................................175 Wheel Hubs And Spindles..............................................................................178 Steer Wheel And Tire.................................................................................180 POWER STEERING SYSTEM....................................................................................181 Power Steering Assembly..............................................................................181 Steering Cylinder....................................................................................182 Wheel Hubs And Spindles..............................................................................183 Checks And Adjustments...............................................................................184 1800205......................................................................................................186 INTRODUCTION.............................................................................................186 General..............................................................................................186 Description..........................................................................................186 REPAIRS..................................................................................................187 Parking Brake Assembly...............................................................................187 ADJUSTMENTS..............................................................................................188 Adjustment of the Hand Brake Linkage.................................................................188 Adjustment of the Linkage for the Hand and Seat Brake................................................188 1800210......................................................................................................189 INTRODUCTION.............................................................................................189 General..............................................................................................189 Description And Operation............................................................................189 REPAIRS..................................................................................................189 Removal And Disassembly..............................................................................189 CHECKS AND ADJUSTMENTS...................................................................................192 Checks...............................................................................................192 Adjustments..........................................................................................192 TROUBLESHOOTING..........................................................................................193 1900161......................................................................................................194 INTRODUCTION.............................................................................................194 General..............................................................................................194 Description..........................................................................................194 The Control Valve....................................................................................196 REPAIRS..................................................................................................201 Hydraulic Pump.......................................................................................201 Main Control Valve...................................................................................203 Hydraulic Pump Contactor.............................................................................208 Contactor Repair.....................................................................................208 CHECKS AND ADJUSTMENTS...................................................................................209 Adjusting The Pressure Relief Valve..................................................................209 Adjustment Of The Control Linkage....................................................................209 Hydraulic Pump Switch................................................................................209 TROUBLESHOOTING..........................................................................................210 2100103......................................................................................................212 General..................................................................................................214 Description..............................................................................................214 Tilt Cylinder............................................................................................214 Remove...............................................................................................214 Disassemble..........................................................................................214 Clean................................................................................................214 Assemble.............................................................................................214 Tilt Cylinders with O-Ring or Single-Lip Seals...................................................214 Tilt Cylinders for XM and XMS Models.............................................................216 Tilt Cylinders for H700-800A and Early Model H700-920B...........................................217 Install..............................................................................................218 Tilt Cylinders Using Chevron Packing.............................................................219 Install......................................................................................220 Tilt Cylinder Leak Check.................................................................................222 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment......................................................223 Torque Specifications....................................................................................223 Piston Rod Nut.......................................................................................223 Retainer.............................................................................................225 Troubleshooting..........................................................................................226 2200143......................................................................................................229 INTRODUCTION.............................................................................................229 GENERAL..............................................................................................229 DESCRIPTION..............................................................................................229 GENERAL..............................................................................................229 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................232 LED DISPLAY PANEL....................................................................................232 Battery Discharge Indicators.....................................................................232 Brush Wear Indicators............................................................................233 Motor Temperature Indicators.....................................................................234 "LX" SERIES DISPLAY PANEL............................................................................235 Hourmeter Functions..............................................................................236 Battery Indicator Function.......................................................................236 Status Code Function.............................................................................236 "ZX" SERIES DISPLAY PANELS...........................................................................236 Display Panel....................................................................................237 Basic Display Panels.............................................................................237 Performance Display..............................................................................239 Brush Wear Indicators............................................................................242 CHECKS AND ADJUSTMENTS...................................................................................242 GENERAL..............................................................................................242 REPLACEMENT..............................................................................................243 GENERAL..............................................................................................243 METER REPLACEMENT....................................................................................243 SENDER REPLACEMENT...................................................................................244 Fuel Level Sender................................................................................244 Pressure And Temperature Sender..................................................................244 I.T.W. DISPLAY PANEL.................................................................................245 Removal..........................................................................................245 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................246 Removal..........................................................................................246 Replacing Display Panel Assembly.................................................................246 Indicator LEDs...................................................................................246 Battery Indicators...............................................................................246 Digital Display (Performance Disply Panel Only)..................................................246 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....246 Replacing Parts Of The Basic Display Panel.......................................................247 Replacing Parts Of The Performance Display Panel.................................................249 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................249 Removal And Replacement..........................................................................249 SPECIFICATIONS...........................................................................................250 TROUBLESHOOTING..........................................................................................251 2200144......................................................................................................252 ELECTRICAL WARNING DEVICES...............................................................................252 GENERAL..............................................................................................252 DESCRIPTION..........................................................................................252 Operator Controlled Horns........................................................................252 System Warning Lights, Buzzers and Bells.........................................................252 Reverse Warning Horns............................................................................253 Warning Lights...................................................................................253 REPLACEMENT..........................................................................................254 General..........................................................................................254 Replacing Horns or Bells.........................................................................254 Replacing Horn Relay or Buzzer...................................................................254 Replacing Warning Lights.........................................................................254 Light Assemblies.................................................................................255 Replacing Flashing Units.........................................................................255 2200464......................................................................................................256 .........................................................................................................256 .........................................................................................................257 .........................................................................................................258 .........................................................................................................259 .........................................................................................................260 .........................................................................................................261 .........................................................................................................262 .........................................................................................................263 .........................................................................................................264 .........................................................................................................265 .........................................................................................................266 .........................................................................................................267 .........................................................................................................268 .........................................................................................................269 .........................................................................................................270 .........................................................................................................271 .........................................................................................................272 .........................................................................................................273 .........................................................................................................274 .........................................................................................................275 .........................................................................................................276 .........................................................................................................277 .........................................................................................................278 .........................................................................................................279 .........................................................................................................280 .........................................................................................................281 .........................................................................................................282 .........................................................................................................283 .........................................................................................................284 .........................................................................................................285 .........................................................................................................286 .........................................................................................................287 .........................................................................................................288 .........................................................................................................289 .........................................................................................................290 .........................................................................................................291 2260138......................................................................................................292 INTRODUCTION.............................................................................................294 GENERAL..............................................................................................294 INDICATORS WITH METER MOVEMENT.......................................................................295 BATTERY INDICATORS WITH LCD OR LED DISPLAYS..........................................................296 Liquid Crystal Displays..........................................................................296 Description, Sem Display Panel...................................................................299 Light Emitting Diode Displays....................................................................300 Description LX Series............................................................................300 Description, ZX Series Display Panels............................................................301 CHECKS AND ADJUSTMENTS...................................................................................302 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS..............................................302 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.................................................302 Reset Potentiometer..............................................................................303 Specific Gravity Alarm...........................................................................303 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS..............................................304 BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS.................................................304 Reset Potentiometer..............................................................................304 Discharge Potentiometer..........................................................................305 LED DISPLAY WITH LIFT INTERRUPT......................................................................305 CHECKING CURTIS 933-1 METER..........................................................................305 Reset Check......................................................................................306 Discharge Check..................................................................................306 Lockout Check....................................................................................307 LED's Do Not Illuminate..........................................................................307 Hour Glass Icon..................................................................................307 ADJUSTMENT OF CURTIS 933-1 METER.....................................................................307 ADJUSTMENT OF SEVCON POWERGAUGE......................................................................308 CURTIS DASH DISPLAY ASSEMBLY.............................................................................308 Description/Features.................................................................................308 Operation............................................................................................309 Testing..............................................................................................309 Inoperative Dash Display Assembly................................................................309 Inoperative drive Mode Selection.................................................................309 Troubleshooting With a Programmer Hand Set.......................................................310 Troubleshooting Without a Programmer Hand Set....................................................310 No Warnings Or Faults Displayed..................................................................311 MIB/Dash Display Communication...................................................................312 Lift Interrupt...................................................................................312 Lost MIB Signal Displayed........................................................................313 Lift Pump Hourmeter Input........................................................................313 Forward/Reverse Hourmeter Inputs.................................................................313 Removal..........................................................................................313 Installation.....................................................................................314 Adjustment (Set-up)..............................................................................314 REPAIRS..................................................................................................315 BATTERY INDICATORS...................................................................................315 Replacement......................................................................................315 CONTROLLER FOR THE BATTERY INDICATOR.................................................................315 Replacement......................................................................................315 DISPLAY PANEL COMPONENTS.............................................................................315 REPLACING SEM DISPLAY PANEL..........................................................................316 SEM DISPLAY PANEL REMOVAL............................................................................316 Removal And Replacement..........................................................................316 4000135......................................................................................................320 Safety Procedures When Working Near Mast.................................................................322 General..................................................................................................327 Description..............................................................................................327 Lowering Control Valve...............................................................................327 Cylinders (General)..................................................................................330 Cylinders (H520-620B, H700-800A).....................................................................330 Retainer, Install................................................................................330 Cylinders (H360-460B)................................................................................332 Cylinders (Two-Speed)................................................................................335 Lift Cylinder Repair.....................................................................................336 Lift Cylinder Removal Without Removing Mast..........................................................336 Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast....................336 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead.......................337 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder.........................338 Disasemble...........................................................................................338 Assemble.............................................................................................338 Lift Cylinder Installation in Mast...................................................................340 Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast.....................340 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead.......................340 Chevron-Style Packing................................................................................340 Chevron-Style Packing Installation on Piston.....................................................341 Chevron-Style Packing Installation in Packing Gland..............................................343 Lift Cylinders for Vista Masts...........................................................................344 Description..........................................................................................344 Lowering Control Valve...........................................................................344 Remove...............................................................................................346 Disassemble..........................................................................................347 Assemble.............................................................................................348 Install..............................................................................................349 Main Lift Cylinders..............................................................................349 Free-Lift Cylinder...............................................................................349 Lift System Leak Check...................................................................................349 Specifications...........................................................................................350 Troubleshooting..........................................................................................351 4000167......................................................................................................354 INTRODUCTION.............................................................................................354 GENERAL..............................................................................................354 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................356 FULL FREE-LIFT MASTS.................................................................................356 THREE-STAGE MASTS....................................................................................358 FOUR-STAGE MASTS.....................................................................................359 SEQUENCE VALVE.......................................................................................359 4000211......................................................................................................361 INTRODUCTION.............................................................................................361 REPAIRS..................................................................................................361 Forks................................................................................................361 Carriage.............................................................................................361 Uprights.............................................................................................363 CHECKS AND ADJUSTMENTS...................................................................................368 Checking For Leaks In The Lift System................................................................368 Adjusting The Tilt Cylinder Stroke And Backward Tilt Angle...........................................369 Upright Adjustments..................................................................................370 TROUBLESHOOTING..........................................................................................374 8000213......................................................................................................375 INTRODUCTION.............................................................................................375 General..............................................................................................375 Moving A Disabled Lift Truck.........................................................................375 MAINTENANCE SCHEDULE.....................................................................................375 MAINTENANCE PROCEDURES...................................................................................377 Every 8 Hours or Daily...............................................................................377 Hydraulic System.................................................................................377 Battery..........................................................................................378 Tires............................................................................................378 Lift Mechanism...................................................................................378 Forks............................................................................................378 Lift Chain.......................................................................................379 Upright..........................................................................................379 Carriage.........................................................................................380 Load Backrest Extension..........................................................................380 Brakes...........................................................................................380 Guages and Horn..................................................................................381 Every 350 Hours or Two Months........................................................................381 Brake Fluid......................................................................................381 Hydraulic Tank Breather..........................................................................382 Differential and Speed Reducer...................................................................382 Uprights.........................................................................................382 Forks............................................................................................382 Electrical Inspection............................................................................384 Every 2000 Hours or Yearly...........................................................................386 Hydraulic System.................................................................................386 Wheel Bearings...................................................................................386 Brake Shoes......................................................................................386 WHEELS AND TIRES.....................................................................................387 CHANGING THE BATTERY.................................................................................389 8000214......................................................................................................390 8000215......................................................................................................393 ELECTRICAL SYSTEM CABLING DIAGRAM........................................................................393 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM 36/48 VOLT (EARLY)...................................................394 ELECTRICAL SYSTEM WIRING DIAGRAM 36/48 VOLT (EARLY)......................................................396 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM 36/48 VOLT (LATER)...................................................398 ELECTRICAL SYSTEM WIRING DIAGRAM 36/48 VOLT (LATER)......................................................400 HYDRAULIC SYSTEM SCHEMATIC...............................................................................402 EV-1 info....................................................................................................403 INTRODUCTION.............................................................................................403 GENERAL..............................................................................................403 PRINCIPLES OF OPERATION..................................................................................403 LIFT TRUCK CONTROL...................................................................................403 ELECTRONIC SPEED CONTROLS............................................................................404 The Silicon Controlled Rectifier (SCR)...........................................................404 The Traction Circuit That Operates With Pulses...................................................404 The SCR 1 OFF Circuit............................................................................408 THE CONTROL CARD FOR THE TRACTION CIRCUIT............................................................408 SRO Circuit......................................................................................409 Pulse Monitor Trip (PMT).........................................................................409 Control Card Adjustments.........................................................................410 C/L (Current Limit)..............................................................................410 Plug.............................................................................................410 Creep............................................................................................411 C/A (Controlled Acceleration)....................................................................411 THERMAL PROTECTION...................................................................................411 THE 1A CIRCUIT.......................................................................................411 FIELD WEAKENING......................................................................................412 RAMP START...........................................................................................413 ACCELERATOR CONTROL..................................................................................413 CONTACTORS AND ELECTRONIC DRIVERS....................................................................413 The Electronic Drivers...........................................................................413 Contactors.......................................................................................413 CIRCUIT PROTECTION...................................................................................415 Current Limit....................................................................................415 Thermal Protection...............................................................................415 Traction Circuit Fuse............................................................................415 SEQUENCE OF OPERATION................................................................................415 EV-1.........................................................................................................426 INTRODUCTION.............................................................................................426 GENERAL..............................................................................................426 SRO CIRCUIT AND PMT CIRCUIT..............................................................................427 STATIC RETURN TO OFF(SRO) CIRCUIT....................................................................427 PULSE MONITOR TRIP (PMT).............................................................................427 THE SEQUENCE OF OPERATION............................................................................428 TROUBLESHOOTING..........................................................................................428 GENERAL PROCEDURES...................................................................................428 FAULT IN THE CONTROL CIRCUIT.....................................................................431 CHECKS AND REPAIRS.......................................................................................446 GENERAL..............................................................................................446 CHECK FOR THE CORRECT OPERATION......................................................................446 CONTROL AND POWER FUSES..............................................................................447 CONTROL CARD.........................................................................................447 Removal..........................................................................................449 Installation.....................................................................................449 SCRs.................................................................................................449 An SCR "QUICK REF"...............................................................................449 Checking An SCR..................................................................................449 The SCR 1 Assembly...............................................................................451 Thermal Sensor...................................................................................451 Checking SCR 1...................................................................................451 Replacing The SCR 1 Assembly.....................................................................451 THE INDUCTOR AND CAPACITOR ASSEMBLY (THE "OFF" CIRCUIT FOR SCR 1)....................................452 Checking The Transformer and Inductor Assembly...................................................452 Checking the Supressors for the SCR 2 and SCR 5..................................................452 Checking the SCR 2 and SCR 5.....................................................................453 Replacing the SCR 2 and SCR 5....................................................................453 Checking The Capacitor C1........................................................................453 D3 And D4 Heat Sink Assembly.....................................................................453 Checking The Diodes D3 and D4....................................................................453 Replacing The Diodes D3 and D4...................................................................454 MOTOR CURRENT SENSOR.................................................................................454 THE ELECTRONIC DRIVER MODULE.........................................................................454 CONTACTORS...........................................................................................455 "FORWARD" And "REVERSE" Contactors...............................................................455 CONTACTOR REPAIR.....................................................................................456 Remove A Contactor Assembly......................................................................456 Contactor Contacts...............................................................................456 Coil.............................................................................................456 CHECK THE PMT CIRCUIT................................................................................457 Fastner info.................................................................................................459 General..................................................................................................461 Nomenclature, Threads................................................................................461 Strength Identification..............................................................................462 Fastener Torque Tables...............................................................................466 Conversion Table.....................................................................................468 Binder2..........................................................................................................470 Battery Discharge Indicators.................................................................................470 INTRODUCTION.............................................................................................470 GENERAL..............................................................................................470 INDICATORS WITH METER MOVEMENTS......................................................................471 BATTERY INDICATORS WITH LCD OR LED DISPLAYS..........................................................472 Liquid Crystal Displays..........................................................................472 Light Emitting Diode Displays....................................................................476 CHECKS AND ADJUSTMENTS...................................................................................478 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS..............................................478 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.................................................478 Reset Potentiometer..............................................................................478 Specific Gravity Alarm...........................................................................479 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS..............................................480 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.................................................480 Reset Potentiometer..............................................................................480 Discharge Potentiometer..........................................................................480 LED DISPLAY WITH LIFT INTERRUPT......................................................................481 CHECKING CURTIS 933-1 METER..........................................................................481 Reset Check......................................................................................481 Discharge Check..................................................................................482 Lockout Check....................................................................................482 LED's Do Not Illuminate..........................................................................483 Hourmeter Check..................................................................................483 Hour Glass Icon..................................................................................483 ADJUSTMENT OF CURTIS 933-1 METER.................................................................483 CHECKING CURTIS 1215 BATTERY INDICATOR...........................................................483 ADJUSTING CURTIS 1215 BATTERY INDICATOR..........................................................484 Voltage Selection............................................................................485 ADJUSTING BDI OF SEM DISPLAY PANEL...............................................................486 REPAIRS..............................................................................................486 BATTERY INDICATORS...............................................................................486 Replacement..................................................................................486 CONTROLLER FOR THE BATTERY INDICATOR.............................................................486 Replacement..................................................................................486 DISPLAY PANEL COMPONENTS.........................................................................486 REPLACING SEM DISPLAY PANEL......................................................................486 SEM Display Panel REMOVAL........................................................................488 Removal And Replacement......................................................................488 Capacities & Specification...................................................................................490 DC Motor Maintenance.........................................................................................493 INTRODUCTION.............................................................................................493 MAGNETISM................................................................................................493 MAGNETISM AND PERMANENT MAGNETS......................................................................493 ELECTROMAGNETIC FIELDS...............................................................................493 ELECTROMAGNETS.......................................................................................494 ELECTROMAGNETIC INDUCTION............................................................................495 MAGNETIC FORCE ON A CONDUCTOR........................................................................495 BASIC MOTORS.............................................................................................496 MOTOR OPERATION......................................................................................496 COMMUTATION PRINCIPLE................................................................................497 DIRECTION OF MOTOR ROTATION..........................................................................497 MOTOR SPEED..........................................................................................497 MOTOR TORQUE.........................................................................................498 COUNTER ELECTROMOTIVE FORCE..........................................................................498 TYPICAL MOTOR........................................................................................498 TYPES OF MOTORS......................................................................................498 Permanent–Magnet.................................................................................498 Series Wound.....................................................................................499 Parallel or Shunt Wound..........................................................................500 Compound Wound...................................................................................500 MOTOR INSULATION CLASS...............................................................................501 STORAGE..............................................................................................501 HANDLING.............................................................................................501 BREAK–IN OPERATION...................................................................................501 CLEANING.............................................................................................502 BASIC REPAIR GUIDELINES..............................................................................502 BEARINGS, SEALS AND LUBRICATION......................................................................503 BRUSHES AND BRUSH HOLDERS............................................................................503 ARMATURE.............................................................................................504 COMMUTATOR...........................................................................................504 Description......................................................................................504 SATISFACTORY SURFACE.................................................................................505 STREAKING AND THREADING SURFACE......................................................................506 GROOVING ON SURFACE..................................................................................507 COPPER DRAG ON SURFACE...............................................................................509 OVERHEATING..........................................................................................509 FIELD ASSEMBLY.......................................................................................511 INSPECTION CHECKLIST.................................................................................511 CHECKING AND REPLACING MOTOR BRUSHES.................................................................511 Inspecting Brushes...............................................................................511 INSPECT THE COMMUTATOR...............................................................................512 REPLACING BRUSHES....................................................................................512 SEATING BRUSHES (STONING PROCEDURE)..................................................................512 CHECK THE MOTORS FOR OPENS, GROUNDS AND SHORTS.......................................................513 Check The Motor For Opens........................................................................513 Check The Motor For Grounds......................................................................513 Check The Motor For Shorts.......................................................................513 COMMUTATOR INSPECTION................................................................................515 POLISHING COMMUTATOR.................................................................................516 TURNING COMMUTATOR...................................................................................516 UNDERCUTTING COMMUTATOR..............................................................................516 SLOT RAKING AND BRUSHING COMMUTATOR..................................................................516 Diagrams.....................................................................................................518 ELECTRICAL SYSTEM CABLING DIAGRAM........................................................................518 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM 36/48 VOLT (EARLY)...................................................519 ELECTRICAL SYSTEM WIRING DIAGRAM 36/48 VOLT (EARLY)......................................................521 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM 36/48 VOLT (LATER)...................................................523 ELECTRICAL SYSTEM WIRING DIAGRAM 36/48 VOLT (LATER)......................................................525 HYDRAULIC SYSTEM SCHEMATIC...............................................................................527 Drive Axle SPD Reducer & Differential........................................................................528 INTRODUCTION.............................................................................................528 General..............................................................................................528 Description..........................................................................................528 REPAIRS..................................................................................................528 Removal Of The Drive Axle (E20-30BS).................................................................528 Installation.........................................................................................530 Removal Of The Drive Axle (E20-30BH).................................................................530 Installation.........................................................................................531 Wheels And Tires.....................................................................................532 Removal Of The Speed Reducer And Differential........................................................533 Disassembly..........................................................................................536 Assembly.............................................................................................537 Installation Of The Drive Assembly...................................................................539 TROUBLESHOOTING..........................................................................................541 Electrical System............................................................................................542 ELECTRICAL CHECKS AND ADJUSTMENTS FOR SitDrive) ELECTRICAL LIFT TRUCKS...................................542 GENERAL..............................................................................................542 CONTROL AND POWER FUSES..............................................................................547 CONTROL CARD ADJUSTMENTS.............................................................................548 Adjusting Creep Speed, "CREEP'...................................................................550 Adjusting Controlled Acceleration, "C/A" ........................................................550 Adjusting Current Limit, "C/L"...................................................................551 Adjust "1A TIME".................................................................................552 Adjust 1A Drop Out, "1A D.O".....................................................................554 Adjust Plugging, "PLUG"..........................................................................554 Ramp Start.......................................................................................554 Adjust Field Weakening Pick Up and Drop Out, "F.W.P.U." And "F.W.D.O."...........................554 Adjust "REGEN C/L" (Current Limit)...............................................................555 Adjust "REGEN D.O." (Drop Out)...................................................................555 PROPORTIONAL CONTROL (J25-35A Only)..................................................................558 SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS..............................................................559 SCR CONTROL, SINGLE PUMP MOTOR.......................................................................559 Accelerator Card (E-20-100B, J40-60AS Only)......................................................560 Circuit Description For Accelerator Card Used With A Seat Switch.................................561 Accelerator "START" (IC3)........................................................................562 Accelertor "1A TIME" (IC2).......................................................................562 Circuit Description For Accelerator Card Used With A Seat Brake..................................562 Accelerator "START" (IC3)........................................................................563 Accelerator "1A TIME" (IC1 and IC2)..............................................................563 CHECK THE ACCELERTOR CARD........................................................................563 ADJUSTING THE ACCELERATOR CARD...................................................................563 THE POTENTIOMETERS AND CONTOL SWITCHES...............................................................563 Steering Potentiometer (J25-35A Only)............................................................563 Accelerator Potentiometer And Start Switch (E20-120XL And J25-60XL Only).........................565 Accelerator Potentiometer And Direction Switch...................................................566 Adjusting Start Switch...........................................................................567 "FORWARD" And "REVERSE" Switch (MONOTROL) (Earlier Production Lift Trucks).......................567 Direction Switches (MONOTROL) (Later Production Lift Trucks).....................................568 "FORWARD" And "REVERSE" Switch (Steering Column).................................................569 Hydraulic Pump Switch............................................................................569 Replace The Key Switch...........................................................................569 Adjust The Seat Switch...........................................................................569 Adjust The Brake Switch..........................................................................570 Parking Brake Switch.............................................................................570 Rocker Switch....................................................................................571 HYDRAULIC PUMP SOFT START (E100-120B Only) (72/80 Volt Only).........................................572 Electrical Warning Devices...................................................................................573 ELECTRICAL WARNING DEVICES...............................................................................573 GENERAL..............................................................................................573 DESCRIPTION..........................................................................................573 Operator Controlled Horns........................................................................573 System Warning Lights, Buzzers and Bells.........................................................573 Reverse Warning Horns............................................................................574 Warning Lights...................................................................................574 REPLACEMENT..........................................................................................575 General..........................................................................................575 Replacing Horns or Bells.........................................................................575 Replacing Horn Relay or Buzzer...................................................................575 Replacing Warning Lights.........................................................................575 Light Assemblies.................................................................................576 Replacing Flashing Units.........................................................................576 EV-1 Motor Controller DESCR & OPER...........................................................................577 INTRODUCTION.............................................................................................577 GENERAL..............................................................................................577 PRINCIPLES OF OPERATION..................................................................................577 LIFT TRUCK CONTROL...................................................................................577 ELECTRONIC SPEED CONTROLS............................................................................578 The Silicon Controlled Rectifier (SCR)...........................................................578 The Traction Circuit That Operates With Pulses...................................................578 The SCR 1 OFF Circuit............................................................................582 THE CONTROL CARD FOR THE TRACTION CIRCUIT............................................................582 SRO Circuit......................................................................................583 Pulse Monitor Trip (PMT).........................................................................583 Control Card Adjustments.........................................................................584 C/L (Current Limit)..............................................................................584 Plug.............................................................................................584 Creep............................................................................................585 C/A (Controlled Acceleration)....................................................................585 THERMAL PROTECTION...................................................................................585 THE 1A CIRCUIT.......................................................................................585 FIELD WEAKENING......................................................................................586 RAMP START...........................................................................................587 ACCELERATOR CONTROL..................................................................................587 CONTACTORS AND ELECTRONIC DRIVERS....................................................................587 The Electronic Drivers...........................................................................587 Contactors.......................................................................................587 CIRCUIT PROTECTION...................................................................................589 Current Limit....................................................................................589 Thermal Protection...............................................................................589 Traction Circuit Fuse............................................................................589 SEQUENCE OF OPERATION................................................................................589 EV-1 Motor Controller Troubleshooting & Repair...............................................................600 INTRODUCTION.............................................................................................600 GENERAL..............................................................................................600 SRO CIRCUIT AND PMT CIRCUIT..............................................................................601 STATIC RETURN TO OFF(SRO) CIRCUIT....................................................................601 PULSE MONITOR TRIP (PMT).............................................................................601 THE SEQUENCE OF OPERATION............................................................................602 TROUBLESHOOTING..........................................................................................602 GENERAL PROCEDURES...................................................................................602 FAULT IN THE CONTROL CIRCUIT.....................................................................605 CHECKS AND REPAIRS.......................................................................................620 GENERAL..............................................................................................620 CHECK FOR THE CORRECT OPERATION......................................................................620 CONTROL AND POWER FUSES..............................................................................621 CONTROL CARD.........................................................................................621 Removal..........................................................................................623 Installation.....................................................................................623 SCRs.................................................................................................623 An SCR "QUICK REF"...............................................................................623 Checking An SCR..................................................................................623 The SCR 1 Assembly...............................................................................625 Thermal Sensor...................................................................................625 Checking SCR 1...................................................................................625 Replacing The SCR 1 Assembly.....................................................................625 THE INDUCTOR AND CAPACITOR ASSEMBLY (THE "OFF" CIRCUIT FOR SCR 1)....................................626 Checking The Transformer and Inductor Assembly...................................................626 Checking the Supressors for the SCR 2 and SCR 5..................................................626 Checking the SCR 2 and SCR 5.....................................................................627 Replacing the SCR 2 and SCR 5....................................................................627 Checking The Capacitor C1........................................................................627 D3 And D4 Heat Sink Assembly.....................................................................627 Checking The Diodes D3 and D4....................................................................627 Replacing The Diodes D3 and D4...................................................................628 MOTOR CURRENT SENSOR.................................................................................628 THE ELECTRONIC DRIVER MODULE.........................................................................628 CONTACTORS...........................................................................................629 "FORWARD" And "REVERSE" Contactors...............................................................629 CONTACTOR REPAIR.....................................................................................630 Remove A Contactor Assembly......................................................................630 Contactor Contacts...............................................................................630 Coil.............................................................................................630 CHECK THE PMT CIRCUIT................................................................................631 Frame........................................................................................................633 INTRODUCTION.............................................................................................633 GENERAL..............................................................................................633 DESCRIPTION..........................................................................................633 DISASSEMBLY AND ASSEMBLY.................................................................................634 OVERHEAD GUARD.......................................................................................634 Removal..........................................................................................634 Installation.....................................................................................634 SEAT ASSEMBLY........................................................................................634 COUNTERWEIGHT........................................................................................634 Removal..........................................................................................635 Installation.....................................................................................635 HYDRAULIC TANK REPAIRS...............................................................................635 Small Leaks......................................................................................635 Large Leaks......................................................................................636 Steam Method Of Cleaning.........................................................................636 Chemical Solution Method of Cleaning.............................................................636 Other Methods....................................................................................636 LABEL REPLACEMENT....................................................................................637 Hydraulic Gear Pump..........................................................................................639 INTRODUCTION.............................................................................................639 DESCRIPTION..........................................................................................639 OPERATION............................................................................................639 Flow Control Valve...............................................................................641 Relief Valve.....................................................................................641 REPAIRS..................................................................................................642 REMOVAL..............................................................................................642 DISASSEMBLY..........................................................................................642 CLEANING.............................................................................................644 INSPECTION...........................................................................................644 ASSEMBLY.............................................................................................645 INSTALLATION.........................................................................................646 CHECKS AND ADUSTMENTS....................................................................................647 CHECK THE OUTPUT OF THE PUMP.........................................................................647 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................647 TROUBLESHOOTING..........................................................................................649 Hydraulic System.............................................................................................652 INTRODUCTION.............................................................................................652 General..............................................................................................652 Description..........................................................................................652 The Control Valve....................................................................................654 REPAIRS..................................................................................................659 Hydraulic Pump.......................................................................................659 Main Control Valve...................................................................................661 Hydraulic Pump Contactor.............................................................................666 Contactor Repair.....................................................................................666 CHECKS AND ADJUSTMENTS...................................................................................667 Adjusting The Pressure Relief Valve..................................................................667 Adjustment Of The Control Linkage....................................................................667 Hydraulic Pump Switch................................................................................667 TROUBLESHOOTING..........................................................................................668 Hydraulic Vane Pump..........................................................................................670 INTRODUCTION.............................................................................................670 GENERAL..............................................................................................670 DESCRIPTION..........................................................................................670 OPERATION............................................................................................670 Pump.............................................................................................670 Relief Valve.....................................................................................671 REPAIRS..................................................................................................672 REMOVAL..............................................................................................672 DISASSEMBLY..........................................................................................672 ASSEMBLY.............................................................................................673 INSTALLATION.........................................................................................674 CHECKS AND ADJUSTMENTS...................................................................................674 CHECKING THE RELIEF PRESSURE OF THE RELIEF VALVE.....................................................674 Lift Trucks With Internal Combustion Engines.....................................................674 Electric Lift Trucks.............................................................................674 Electric Lift Trucks With Adjustable Relief Valve................................................675 SPECIFICATIONS...........................................................................................676 TROUBLESHOOTING..........................................................................................676 Industrial Battery...........................................................................................677 INTRODUCTION.............................................................................................677 GENERAL..............................................................................................677 LEAD-ACID BATTERIES..................................................................................677 SPECIFIC GRAVITY.....................................................................................678 CHEMICAL REACTION IN A CELL..........................................................................678 ELECTRICAL TERMS.....................................................................................679 HOW TO SELECT THE BATTERY............................................................................679 VOLTAGE OF A BATTERY.................................................................................679 THE BATTERY AS A COUNTERWEIGHT.......................................................................680 BATTERY RATINGS......................................................................................680 Kilowatt-Hours...................................................................................681 BATTERY MAINTENANCE......................................................................................681 SAFETY PROCEDURES....................................................................................681 MAINTENCE RECORDS....................................................................................682 THE NEW BATTERY......................................................................................682 HOW TO CLEAN THE BATTERY.............................................................................683 HOW TO ADD WATER.....................................................................................683 THE HYDROMETER.......................................................................................684 BATTERY TEMPERATURE..................................................................................684 CHARGING THE BATTERY.................................................................................685 Types Of Battery Charges.........................................................................686 Methods Of Charging..............................................................................687 Troubleshooting The Charger......................................................................687 How to Know When The Battery Is Fully Charged....................................................688 WHERE TO CHARGE THE BATTERIES........................................................................688 Equipment Needed.................................................................................688 BATTERY CONNECTORS...................................................................................689 BATTERY CARE.........................................................................................689 Lift Cylinders...............................................................................................691 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................691 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................691 LIFT CYLINDERS...........................................................................................694 GENERAL..............................................................................................694 DESCRIPTION..........................................................................................694 Lowering Control Valve...........................................................................694 Cylinders (General)..............................................................................697 Cylinders (H520-620B,H700-800A)..................................................................699 Cylinders (H360-460B)............................................................................700 Cylinders (Two-Speed)............................................................................700 REPAIRS..................................................................................................701 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................701 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........701 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................705 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................703 DISASSEMBLY..........................................................................................703 ASSEMBLY.............................................................................................705 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................705 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........705 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................705 CHEVRON PACKING......................................................................................706 LIFT CYLINDERS FOR VISTA MASTS...........................................................................709 DESCRIPTION..........................................................................................709 Lowering Control Valve...........................................................................711 REMOVAL..............................................................................................712 DISASSEMBLY..........................................................................................712 ASSEMBLY.............................................................................................712 INSTALLATION.........................................................................................713 Main Lift Cylinders..............................................................................713 Free-Lift Cylinders..............................................................................713 CHECKS AND ADJUSTMENTS...................................................................................714 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................714 TROUBLESHOOTING..........................................................................................715 SPECIFICATIONS...........................................................................................716 Mast Description.............................................................................................717 INTRODUCTION.............................................................................................717 GENERAL..............................................................................................717 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................719 FULL FREE-LIFT MASTS.................................................................................719 THREE-STAGE MASTS....................................................................................721 FOUR-STAGE MASTS.....................................................................................722 SEQUENCE VALVE.......................................................................................722 Mast Repair..................................................................................................724 INTRODUCTION.............................................................................................724 REPAIRS..................................................................................................724 Forks................................................................................................724 Carriage.............................................................................................724 Uprights.............................................................................................726 CHECKS AND ADJUSTMENTS...................................................................................731 Checking For Leaks In The Lift System................................................................731 Adjusting The Tilt Cylinder Stroke And Backward Tilt Angle...........................................732 Upright Adjustments..................................................................................733 TROUBLESHOOTING..........................................................................................737 Master Cylinder..............................................................................................738 INTRODUCTION.............................................................................................738 GENERAL..............................................................................................738 DESCRIPTION..........................................................................................738 REPAIRS..................................................................................................738 REMOVAL AND DISASSEMBLY..............................................................................738 CLEANING ............................................................................................739 ASSEMBLY.............................................................................................739 CHECKS AND ADJUSTMENTS...................................................................................739 CHECKS...............................................................................................739 Parking Brake................................................................................................740 INTRODUCTION.............................................................................................740 General..............................................................................................740 Description..........................................................................................740 REPAIRS..................................................................................................741 Parking Brake Assembly...............................................................................741 ADJUSTMENTS..............................................................................................742 Adjustment of the Hand Brake Linkage.................................................................742 Adjustment of the Linkage for the Hand and Seat Brake................................................742 Periodic Maintenance.........................................................................................743 INTRODUCTION.............................................................................................743 General..............................................................................................743 Moving A Disabled Lift Truck.........................................................................743 MAINTENANCE SCHEDULE.....................................................................................743 MAINTENANCE PROCEDURES...................................................................................745 Every 8 Hours or Daily...............................................................................745 Hydraulic System.................................................................................745 Battery..........................................................................................746 Tires............................................................................................746 Lift Mechanism...................................................................................746 Forks............................................................................................746 Lift Chain.......................................................................................747 Upright..........................................................................................747 Carriage.........................................................................................748 Load Backrest Extension..........................................................................748 Brakes...........................................................................................748 Guages and Horn..................................................................................749 Every 350 Hours or Two Months........................................................................749 Brake Fluid......................................................................................749 Hydraulic Tank Breather..........................................................................750 Differential and Speed Reducer...................................................................750 Uprights.........................................................................................750 Forks............................................................................................750 Electrical Inspection............................................................................752 Every 2000 Hours or Yearly...........................................................................754 Hydraulic System.................................................................................754 Wheel Bearings...................................................................................754 Brake Shoes......................................................................................754 WHEELS AND TIRES.....................................................................................755 CHANGING THE BATTERY.................................................................................757 SAE & Metric Fasteners.......................................................................................758 INTRODUCTION.............................................................................................758 NOMENCLATURE, THREADS................................................................................758 STRENGTH IDENTIFICATION..............................................................................759 TABLE 1. BOLTS AND SCREWS................................................................................759 TABLE 2. STUDS AND NUTS..................................................................................760 TABLE 3. TORQUE NUTS.....................................................................................761 TABLE 4. TORQUE NUTS WITH NYLON INSERT...................................................................762 TABLE 5. TORQUE VALUES FOR INCH FASTENERS................................................................763 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..............................................................764 Service Brakes...............................................................................................767 INTRODUCTION.............................................................................................767 General..............................................................................................767 Description And Operation............................................................................767 REPAIRS..................................................................................................767 Removal And Disassembly..............................................................................767 CHECKS AND ADJUSTMENTS...................................................................................770 Checks...............................................................................................770 Adjustments..........................................................................................770 TROUBLESHOOTING..........................................................................................771 Steering Control Unit........................................................................................772 INTRODUCTION.............................................................................................772 GENERAL..............................................................................................772 DESCRIPTION..........................................................................................772 OPERATION............................................................................................772 REPAIRS..................................................................................................772 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................772 TYPE "A" STEERING COLUMN ASSEMBLY....................................................................774 Removal And Disassembly..........................................................................774 Assembly And Installation........................................................................774 TYPE "A" STEERING COLUMN.............................................................................775 TYPE "A" STEERING COLUMN.............................................................................776 TYPE "B" STEERING COLUMN.............................................................................777 Removal And Disassembly..........................................................................777 Assembly And Installation........................................................................777 TYPE "B" STEERING COLUMN.............................................................................778 Disassembly of Steering Control Unit.............................................................779 Cleaning of Steering Control Unit................................................................779 Assembly of Steering Control Unit................................................................781 CHECKS AND ADJUSTMENTS...................................................................................784 REMOVE AIR FROM THE SYSTEM...........................................................................784 TROUBLESHOOTING..........................................................................................785 Steering System..............................................................................................786 MANUAL STEERING SYSTEM (E20-30BS)........................................................................786 System Description...................................................................................787 Steering Wheel Assembly..............................................................................787 Steering Column Assembly.............................................................................788 Steering Gear Assembly...............................................................................790 Tie Rods And Drag Link...............................................................................796 Steering Axle Assembly...............................................................................797 Wheel Hubs And Spindles..............................................................................802 POWER STEERING SYSTEM....................................................................................805 System Description...................................................................................805 Steering Wheel And Column Assembly...................................................................806 Steering Control Unit................................................................................808 Power Steering Motor And Pump........................................................................808 Power Steering Axle Assembly.........................................................................809 Steering Cylinder....................................................................................810 Wheel Hubs And Spindles..............................................................................814 Inspection Requirements..............................................................................814 Manual Steering Checks And Adjustments...............................................................819 E20-30BH STEERING SYSTEM SUPPLEMENT......................................................................821 MANUAL STEERING SYSTEM...................................................................................821 Steering Axle Assembly...............................................................................821 Wheel Hubs And Spindles..............................................................................824 Steer Wheel And Tire.................................................................................826 POWER STEERING SYSTEM....................................................................................827 Power Steering Assembly..............................................................................827 Steering Cylinder....................................................................................828 Wheel Hubs And Spindles..............................................................................829 Checks And Adjustments...............................................................................830 Tilt Cylinder................................................................................................832 INTRODUCTION.............................................................................................832 GENERAL..............................................................................................832 DESCRIPTION..........................................................................................832 REPAIRS..................................................................................................832 REMOVAL..............................................................................................832 DISASSEMBLY..........................................................................................832 CLEANING.............................................................................................832 ASSEMBLY.............................................................................................832 Tilt Cylinders with O-Rings or Single Lip Seals..................................................832 Tilt Cylinders for the XM and XMS Models.........................................................833 Tilt Cylinders for H700 800A and Early Model H700 920B...........................................835 INSTALLATION.........................................................................................835 Tilt Cylinders Using Chevron Packing.............................................................836 CHECKS AND ADJUSTMENTS...................................................................................838 CHECK THE TILT CYLINDERS FOR LEAKS...................................................................838 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..............................................838 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS.................................................839 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS................................................840 TROUBLESHOOTING..........................................................................................842
HYSTER B114 (E20-25B, E30BS) SERVICE MANUAL – PDF DOWNLOAD:
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