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Hyster C098 (E70-120XL) Service Manual – PDF DOWNLOAD
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Description
Hyster C098 (E70-120XL) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C098 (E70-120XL) Service Manual – PDF DOWNLOAD
Language : English
Pages : 805
Downloadable : Yes
File Type : PDF
Size: 20.9 MB
TABLE OF CONTENTS:
Hyster C098 (E70-120XL) Service Manual – PDF DOWNLOAD
Battery Discharge Indicators.................................................................................................................... 1 INTRODUCTION................................................................................................................................ 1 GENERAL................................................................................................................................. 1 INDICATORS WITH METER MOVEMENTS......................................................................................................... 2 BATTERY INDICATORS WITH LCD OR LED DISPLAYS............................................................................................. 3 Liquid Crystal Displays............................................................................................................. 3 Light Emitting Diode Displays....................................................................................................... 7 CHECKS AND ADJUSTMENTS...................................................................................................................... 9 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS................................................................................. 9 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.................................................................................... 9 Reset Potentiometer................................................................................................................. 9 Specific Gravity Alarm.............................................................................................................. 10 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS................................................................................. 11 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.................................................................................... 11 Reset Potentiometer................................................................................................................. 11 Discharge Potentiometer............................................................................................................. 11 LED DISPLAY WITH LIFT INTERRUPT......................................................................................................... 12 CHECKING CURTIS 933-1 METER............................................................................................................. 12 Reset Check......................................................................................................................... 12 Discharge Check..................................................................................................................... 13 Lockout Check....................................................................................................................... 13 LED's Do Not Illuminate............................................................................................................. 14 Hourmeter Check..................................................................................................................... 14 Hour Glass Icon..................................................................................................................... 14 ADJUSTMENT OF CURTIS 933-1 METER.................................................................................................... 14 CHECKING CURTIS 1215 BATTERY INDICATOR.............................................................................................. 14 ADJUSTING CURTIS 1215 BATTERY INDICATOR............................................................................................. 15 Voltage Selection............................................................................................................... 16 ADJUSTING BDI OF SEM DISPLAY PANEL.................................................................................................. 17 REPAIRS................................................................................................................................. 17 BATTERY INDICATORS.................................................................................................................. 17 Replacement..................................................................................................................... 17 CONTROLLER FOR THE BATTERY INDICATOR................................................................................................ 17 Replacement..................................................................................................................... 17 DISPLAY PANEL COMPONENTS............................................................................................................ 17 REPLACING SEM DISPLAY PANEL......................................................................................................... 17 SEM Display Panel REMOVAL........................................................................................................... 19 Removal And Replacement......................................................................................................... 19 Brake System.................................................................................................................................... 21 BRAKE SYSTEM................................................................................................................................ 21 GENERAL................................................................................................................................. 21 DESCRIPTION AND OPERATION............................................................................................................... 21 BRAKE BOOSTER AND MASTER CYLINDER....................................................................................................... 21 MASTER CYLINDER......................................................................................................................... 21 BRAKE SERVICE ASSEMBLY.................................................................................................................. 23 PARKING BRAKE........................................................................................................................... 24 REPAIRS..................................................................................................................................... 24 BRAKE SHOE ASSEMBLIES................................................................................................................... 24 Removal and Disassembly............................................................................................................. 24 Cleaning and Inspection............................................................................................................. 25 Assembly and Installation........................................................................................................... 27 MASTER CYLINDER, S3.50-5.50XL (S70-120XL) and H3.50-5.00XL (H70-110XL).................................................................. 30 Removal............................................................................................................................. 30 Disassembly......................................................................................................................... 30 Assembly............................................................................................................................ 31 Installation........................................................................................................................ 31 MASTER CYLINDER, E3.50-5.50L (E70-120XL, E70-120XL3).................................................................................... 31 Removal and Disassembly............................................................................................................. 31 Cleaning and Inspection............................................................................................................. 32 Assembly and Installation........................................................................................................... 32 BRAKE BOOSTER........................................................................................................................... 32 Removal............................................................................................................................. 32 Disassembly......................................................................................................................... 32 Cleaning and Inspection............................................................................................................. 33 Assembly............................................................................................................................ 33 Installation........................................................................................................................ 34 CHECKS AND ADJUSTMENTS...................................................................................................................... 34 REMOVE THE AIR FROM THE BRAKE SYSTEM.................................................................................................... 34 ADJUST THE BRAKE PEDAL, H3.50-5.00XL (H70-110XL) With Manual Transmission and E3.50-5.50 (E70-120XL, E70-120XL3)........................ 34 ADJUST THE BRAKE SHOES.................................................................................................................. 36 ADJUST THE PARKING BRAKE, S3.50-5.50XL (S70-120XL) H3.50-5.00XL (H70-110XL)............................................................. 37 ADJUST THE PARKING BRAKE LEVER AND SWITCH, E3.50-5.50XL (E70-120XL, E70-120XL3)......................................................... 37 CHECK THE RELIEF VALVE ON THE BRAKE BOOSTER............................................................................................. 37 TROUBLESHOOTING............................................................................................................................. 38 Capacities & Specification...................................................................................................................... 40 DC Motor Maintenance............................................................................................................................ 49 INTRODUCTION................................................................................................................................ 49 ELECTRIC MOTOR MAINTENANCE, GENERAL..................................................................................................... 49 BRUSH AND COMMUNICATOR INSPECTION....................................................................................................... 49 Hydraulic Pump Motor And Traction Motor............................................................................................. 49 Steering Pump Motor................................................................................................................. 51 BRUSH WEAR REPLACEMENT GUIDE................................................................................................................ 51 Commutator Problems..................................................................................................................... 53 BRUSH REPLACEMENTS...................................................................................................................... 55 DISASSEMBLY OF MOTORS................................................................................................................... 57 Traction Motor And Hydraulic Pump Motor............................................................................................. 57 Steering Pump Motor................................................................................................................. 63 ASSEMBLY OF MOTORS...................................................................................................................... 65 Traction Motor And Hydraulic Pump Motor ............................................................................................ 65 Steering Pump Motor................................................................................................................. 65 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS.......................................................................................... 65 TESTS FOR A DAMAGED FIELD AND ARMATURE.................................................................................................. 66 Test For An Open Circuit In The Armature............................................................................................ 66 Test For A Short-Circuit In One Armature Winding.................................................................................... 66 Test For A Short-Circuit To Armature Shaft.......................................................................................... 67 Test For An Open Circuit In A Field Coil............................................................................................ 67 Test For A Short-Circuit In A Field Coil............................................................................................ 67 Test For A Short-Circuit Between The Field And The Motor Case....................................................................... 68 Brush Holder Test................................................................................................................... 68 TROUBLESHOOTING............................................................................................................................. 68 Diagrams EV-100-200 Motor Controller............................................................................................................ 70 FIGURE 1. SCHEMATIC DIAGRAM, EV–100 OR EV–200 SCR TRACTION MOTOR CONTROL, 36–48 VOLTS....................................................... 71 FIGURE 2. WIRING DIAGRAM, EV–100 SCR TRACTION MOTOR CONTROL WITH SINGLE OR DUAL HYDRAULIC PUMP MOTOR CONTACTOR CONTROL...................... 73 FIGURE 3. WIRING DIAGRAM, EV–200 SCR TRACTION MOTOR CONTROL WITH EV–100 SCR HYDRAULIC PUMP MOTOR CONTROL.................................... 75 FIGURE 4. WIRING DIAGRAM, CONTROL SWITCHES.................................................................................................. 77 FIGURE 5. HYDRAULIC PUMP MOTOR CONTROLS (1 OF 3)............................................................................................ 79 FIGURE 6. BATTERY INDICATORS................................................................................................................ 84 FIGURE 7. HYDRAULIC SCHEMATIC............................................................................................................... 85 FIGURE 8. SCHEMATIC AND WIRING DIAGRAM – 12V LIGHTS......................................................................................... 87 Diagrams EV-100-200LX Motor Controller.......................................................................................................... 88 FIGURE 1. SCHEMATIC DIAGRAM, EV-100 OR EV-200 SCR TRACTION MOTOR CONTROL, 36-48 VOLTS....................................................... 89 FIGURE 2. WIRING DIAGRAM, EV-100 SCR TRACTION MOTOR CONTROL WITH SINGLE OR DUAL HYDRAULIC PUMP MOTOR CONTACTOR CONTROL...................... 91 FIGURE 3. WIRING DIAGRAM, EV-200 SCR TRACTION MOTOR CONTROL WITH EV-100 SCR HYDRAULIC PUMP MOTOR CONTROL.................................... 93 FIGURE 4. WIRING DIAGRAM, CONTROL SWITCHES (1 OF 2)......................................................................................... 95 FIGURE 5. HYDRAULIC PUMP MOTOR CONTROLS (1 OF 4)............................................................................................ 99 FIGURE 6. EV-100 "LX" SERIES GE OR ITW DISPLAY WITH LIFT INTERRUPT - WITHOUT PUMP MOTOR SCR CONTROL SCHEMATIC...............................106 FIGURE 7. BATTERY INDICATORS................................................................................................................107 Diagrams EV-100ZX Motor Controller..............................................................................................................108 FIGURE 1. HYDRAULIC SCHEMATIC...............................................................................................................108 FIGURE 2. SCHEMATIC DIAGRAM, EV-100ZX OR EV-200ZX SCR MOTOR CONTROLLERS, 36-48 VOLTS........................................................110 FIGURE 3. WIRING DIAGRAM, EV-100ZX OR EV-200ZX SCR MOTOR CONTROLLERS, 36-48 VOLTS...........................................................116 FIGURE 4. CABLE DIAGRAM, EV-100ZX OR EV200-ZX SCR MOTOR CONTROLLERS, 36-48 VOLTS............................................................126 FIGURE 5. DETAIL DIAGRAM, EV-100ZX OR EV-200ZX SCR MOTOR CONTROLLERS, 36-48 VOLTS...........................................................127 FIGURE 6. CONTROL PANELS, EV100ZX OR EV-200ZX SCR MOTOR CONTROLLERS, 36-48 VOLTS............................................................128 FIGURE 7. SCHEMATIC AND WIRING DIAGRAM - 12V LIGHTS.........................................................................................130 Drive Axle Speed Reducer & Differential.........................................................................................................131 DRIVE AXLE..................................................................................................................................131 GENERAL.................................................................................................................................131 DESCRIPTION.............................................................................................................................131 REPAIRS.....................................................................................................................................132 REMOVAL.................................................................................................................................132 General.............................................................................................................................132 Traction Motor, Speed Reducer, and Differential.....................................................................................132 DISASSEMBLY.............................................................................................................................135 Speed Reducer.......................................................................................................................135 Differential........................................................................................................................135 CLEANING................................................................................................................................135 INSPECTION..............................................................................................................................135 ASSEMBLY................................................................................................................................136 Speed Reducer.......................................................................................................................136 ADJUSTMENTS OF SHIMS FOR THE PINION ASSEMBLY............................................................................................137 Differential........................................................................................................................138 DRIVE AXLE HOUSING......................................................................................................................139 Removal.............................................................................................................................139 Cleaning............................................................................................................................141 Inspection..........................................................................................................................141 Assembly............................................................................................................................141 TROUBLESHOOTING.............................................................................................................................144 Electrical System (trucks with controller prior to ZX)..........................................................................................145 ELECTRICAL CHECKS AND ADJUSTMENTS FOR SitDrive) ELECTRICAL LIFT TRUCKS......................................................................145 GENERAL.................................................................................................................................145 CONTROL AND POWER FUSES.................................................................................................................150 CONTROL CARD ADJUSTMENTS................................................................................................................151 Adjusting Creep Speed, "CREEP'......................................................................................................153 Adjusting Controlled Acceleration, "C/A" ...........................................................................................153 Adjusting Current Limit, "C/L"......................................................................................................154 Adjust "1A TIME"....................................................................................................................155 Adjust 1A Drop Out, "1A D.O"........................................................................................................157 Adjust Plugging, "PLUG".............................................................................................................157 Ramp Start..........................................................................................................................157 Adjust Field Weakening Pick Up and Drop Out, "F.W.P.U." And "F.W.D.O."..............................................................157 Adjust "REGEN C/L" (Current Limit)..................................................................................................158 Adjust "REGEN D.O." (Drop Out)......................................................................................................158 PROPORTIONAL CONTROL (J25-35A Only).....................................................................................................161 SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS.................................................................................................162 SCR CONTROL, SINGLE PUMP MOTOR..........................................................................................................162 Accelerator Card (E-20-100B, J40-60AS Only).........................................................................................163 Circuit Description For Accelerator Card Used With A Seat Switch....................................................................164 Accelerator "START" (IC3)...........................................................................................................165 Accelertor "1A TIME" (IC2)..........................................................................................................165 Circuit Description For Accelerator Card Used With A Seat Brake.....................................................................165 Accelerator "START" (IC3)...........................................................................................................166 Accelerator "1A TIME" (IC1 and IC2).................................................................................................166 CHECK THE ACCELERTOR CARD...........................................................................................................166 ADJUSTING THE ACCELERATOR CARD......................................................................................................166 THE POTENTIOMETERS AND CONTOL SWITCHES..................................................................................................166 Steering Potentiometer (J25-35A Only)...............................................................................................166 Accelerator Potentiometer And Start Switch (E20-120XL And J25-60XL Only)............................................................168 Accelerator Potentiometer And Direction Switch......................................................................................169 Adjusting Start Switch..............................................................................................................170 "FORWARD" And "REVERSE" Switch (MONOTROL) (Earlier Production Lift Trucks)..........................................................170 Direction Switches (MONOTROL) (Later Production Lift Trucks)........................................................................171 "FORWARD" And "REVERSE" Switch (Steering Column)....................................................................................172 Hydraulic Pump Switch...............................................................................................................172 Replace The Key Switch..............................................................................................................172 Adjust The Seat Switch..............................................................................................................172 Adjust The Brake Switch.............................................................................................................173 Parking Brake Switch................................................................................................................173 Rocker Switch.......................................................................................................................174 HYDRAULIC PUMP SOFT START (E100-120B Only) (72/80 Volt Only)............................................................................175 Electrical System (trucks with ZX controllers)..................................................................................................176 ELECTRICAL SYSTEM...........................................................................................................................176 GENERAL.................................................................................................................................176 "LX" SERIES DISPLAY PANEL...............................................................................................................177 Hourmeter Functions.................................................................................................................178 Battery Indicator Function..........................................................................................................178 Status Code Function................................................................................................................179 "ZX" SERIES DISPLAY PANELS..............................................................................................................179 Display Panel.......................................................................................................................179 Basic Display Panels................................................................................................................179 Performance Display.................................................................................................................181 Brush Wear Indicators...............................................................................................................184 SEM DISPLAY PANELS - FEATURES...........................................................................................................184 Description Of Common Features......................................................................................................185 LED SYMBOL INDICATORS...............................................................................................................185 LCD SCREEN..........................................................................................................................185 BATTERY DISCHARGE INDICATOR (BDI)...................................................................................................185 SERVICE REMINDER....................................................................................................................185 STATUS CODES........................................................................................................................185 HOURMETER...........................................................................................................................185 Additional Features Of Premium Display Panel .......................................................................................185 Descriptions Of Additional Features (Available With The Premium Display) ...........................................................186 LCD SCREEN..........................................................................................................................186 OPERATOR PASSWORDS..................................................................................................................186 DAILY CHECK LIST AND SERVICE ITEMS..................................................................................................186 PERFORMANCE MODELS..................................................................................................................186 STATUS CODE LISTS...................................................................................................................186 ADJUSTMENTS OF BDI..................................................................................................................187 SEM DISPLAY PANEL INDICATORS............................................................................................................187 All Indicator Symbols...............................................................................................................187 Hourmeter Indicator Symbol..........................................................................................................188 Wrench Indicator Symbol.............................................................................................................188 Battery Indicator Symbol............................................................................................................188 Battery State-Of-Charge (BDI).......................................................................................................188 Brake Fluid Too Low Symbol..........................................................................................................188 Parking Brake Symbol................................................................................................................188 Fasten Seat Belt Symbol.............................................................................................................188 LCD "Screen" (Standard Display Panel)...............................................................................................188 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM.................................................................................188 Alpha Numeric "Screen"..............................................................................................................188 "Star" Push Button..................................................................................................................189 Push Buttons #1 Through #5..........................................................................................................189 OTHER CONTROL COMPONENTS................................................................................................................189 REPLACEMENT.................................................................................................................................190 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"................................................................................................190 Replace The Display Panel Assembly..................................................................................................190 Replace The Key Switch..............................................................................................................191 Indicator LEDs......................................................................................................................191 Battery Indicators..................................................................................................................191 Digital Display (Performance Display Panel Only) ...................................................................................191 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only)........................................193 Replace Parts Of The Basic Display Panel ...........................................................................................193 Replace Parts Of The Performance Display Panel......................................................................................194 SEM DISPLAY PANEL.......................................................................................................................195 Removal And Replacement.............................................................................................................195 REPLACE MOTOR CONTROLLER (SR or SP).....................................................................................................195 OTHER CONTROL COMPONENTS................................................................................................................195 Start Swtich........................................................................................................................195 Brake Light Switch..................................................................................................................196 Seat Switch.........................................................................................................................197 Adjust The External Seat Switch.....................................................................................................198 Switch For Optional Seat Brake......................................................................................................198 Parking Brake Switch................................................................................................................198 Direction Switches (Monotrol Pedal)................................................................................................199 Direction Control Switches (Steering Column)........................................................................................200 Direction Control Switches, E70-120XL3 (Steering Column)............................................................................201 Brake Fluid Switch..................................................................................................................201 Brush Wear And Over Temperature Sensors.............................................................................................201 Rocker Switches For Lights .........................................................................................................202 Accelerator Position Sensor.........................................................................................................202 On-Demand Steering Components.......................................................................................................204 Lights, Converter, Relay And Reverse Alarm..........................................................................................206 Horn And Horn Buttons...............................................................................................................209 Hydraulic Pump Switches.............................................................................................................210 CHECKS AND ADJUSTMENTS......................................................................................................................210 GENERAL.................................................................................................................................210 CONTROL AND POWER FUSES - "LX" OR "ZX"..................................................................................................210 CONTROL AND POWER FUSES - SEM...........................................................................................................213 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"............................................................................216 THERMAL SENSORS - SEM...................................................................................................................216 ADJUST THE START SWITCH.................................................................................................................216 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3...................................................................217 Direction Switches (MONOTROL).......................................................................................................219 ADJUST THE BRAKE LIGHT SWITCH.......................................................................................................219 CHECK SEAT SWITCH...................................................................................................................219 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE...........................................................................................219 ADJUST THE PARKING BRAKE SWITCH.....................................................................................................220 DIRECTIONAL SWITCHES................................................................................................................220 DIRECTIONAL SWITCHES (STEERING COLUMN)..............................................................................................220 HYDRAULIC PUMP SWITCHES.............................................................................................................220 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT......................................................................................220 ADJUST THE ACCELERATOR POSITION SENSOR..............................................................................................221 EV-100 Motor Controller Description & Operation.................................................................................................223 EV-100E MOTOR CONTROLLER, DESCRIPTION AND OPERATION.........................................................................................223 GENERAL.................................................................................................................................223 ELECTRONIC SPEED CONTROLS...............................................................................................................224 The Silicon Controlled Rectifier (SCR)..............................................................................................224 A Motor Circuit That Operates With Pulses...........................................................................................225 Traction Circuit....................................................................................................................227 Hydraulic Motor Circuit.............................................................................................................227 The SCR 1 "OFF" Circuit.............................................................................................................227 INDUCTION CURRENT FROM THE MOTOR........................................................................................................229 THE CONTROL CARD........................................................................................................................234 Pulse Monitor Trip (PMT) (Traction Circuit Only)....................................................................................235 SRO Circuit (Traction Circuit Only).................................................................................................236 Control Card Adjustments (Traction Circuit).........................................................................................236 Accelerator Control.................................................................................................................240 Dual Motor "Plugging" (J25-35B).....................................................................................................240 SCR CONTROL (HYDRAULIC PUMP MOTOR)......................................................................................................241 CONTACTORS AND ELECTRONIC DRIVERS (TRACTION CIRCUIT)....................................................................................242 The Electronic Drivers..............................................................................................................242 Contactors..........................................................................................................................243 CIRCUIT PROTECTION......................................................................................................................244 Current Limit.......................................................................................................................244 Thermal Protection..................................................................................................................244 Suppressors.........................................................................................................................244 Traction Circuit Fuse...............................................................................................................245 SEQUENCE OF OPERATION.......................................................................................................................245 EV-100 Motor Controller Repair..................................................................................................................258 EV-100 MOTOR CONTROLLER REPAIRS AND ADJUSTMENTS.............................................................................................258 GENERAL.................................................................................................................................258 FUSES...................................................................................................................................263 CONTROL CARD............................................................................................................................264 The Control Card Plugs..............................................................................................................266 HOW TO CHECK AN SCR.....................................................................................................................266 The SCR Assembly....................................................................................................................267 Thermal Protector...................................................................................................................267 How To Replace The SCR 1 Assembly...................................................................................................267 THE "OFF" CIRCUIT FOR SCR 1.............................................................................................................268 Check The Inductor Assembly.........................................................................................................268 Check Suppressors For SCR 2 And SCR 5...............................................................................................268 Check SCR 2 And SCR 5...............................................................................................................269 Replace The SCR 2 And SCR 5.........................................................................................................269 Check Capacitor C1..................................................................................................................270 DIODES D3 AND D4........................................................................................................................270 Check The Diodes D3 and D4..........................................................................................................270 Replacement, Diodes D3 and D4.......................................................................................................270 MOTOR CURRENT SENSOR....................................................................................................................270 THE ELECTRONIC DRIVER MODULE............................................................................................................270 CONTACTORS..............................................................................................................................271 CONTACTOR REPAIR........................................................................................................................272 Removing A Contactor Assembly.......................................................................................................272 Contactor Contacts..................................................................................................................272 Coil................................................................................................................................273 CONTROL CARD ADJUSTMENTS................................................................................................................275 "CREEP".............................................................................................................................275 "C/A" (Controlled Acceleration).....................................................................................................275 "C/L"...............................................................................................................................275 "1A TIME"...........................................................................................................................276 "PLUG"..............................................................................................................................277 "F.W.P.U. and "F.W.D.O."............................................................................................................277 "REGEN C/L".........................................................................................................................277 "REGEN D.O."........................................................................................................................277 VOLTAGE ADJUSTMENTS, SCR CONTROL FOR HYDRAULIC PUMP.....................................................................................277 EV-100 Motor Controller Troubleshooting.........................................................................................................281 INTRODUCTION................................................................................................................................281 GENERAL.................................................................................................................................281 SRO CIRCUIT AND PMT CIRCUIT (TRACTION CIRCUIT)..............................................................................................284 STATIC RETURN TO OFF (SRO) CIRCUIT......................................................................................................284 PULSE MONITOR TRIP (PMT)................................................................................................................284 THE SEQUENCE OF OPERATION (TRACTION CIRCUIT)............................................................................................284 CHECKING FOR THE CORRECT OPERATION......................................................................................................285 TROUBLESHOOTING.............................................................................................................................286 GENERAL PROCEDURES......................................................................................................................287 FAULT NUMBER 1. The Direction Contactors Will Not Close For Operation In Either Direction...........................................289 LIFT TRUCKS WITHOUT REGENERATIVE BRAKING....................................................................................................289 GENERAL PROCEDURES......................................................................................................................287 FAULT NUMBER 2. Lift Truck Will Not Move In Either Direction. The Direction Contactors Close And Then Immediately Open (PMT Fau....292 FAULT NUMBER 3. Lift Truck Will Not Move In Either Direction. The Direction Contactors Close Normally (No PMT Fault)................294 FAULT NUMBER 4. Lift Truck Will Not Move In One Direction. The Direction Contactors Close Normally (No PMT Fault)...................296 FAULT NUMBER 5. One Direction Contactor Will Not Close. Traction Circuit Operates Normally In Only One Direction...................296 FAULT NUMBER 6. Plugging Problems...................................................................................................297 FAULT NUMBER 7. Direction Contactors Close Normally. The Lift Truck Has Only Low Power Or Moves Slowly.............................298 FAULT NUMBER 8. Contactor 1a Will Not Energize. The Other Operations Of The Lift Truck Are Normal..................................299 FAULT NUMBER 1R. Regenerative Braking Contactor Does Not Close. The "forward" And "reverse" Contactors Will Close. The Lift Tr....300 LIFT TRUCKS EQUIPPED WITH REGENERATIVE BRAKING..............................................................................................300 GENERAL PROCEDURES......................................................................................................................287 FAULT NUMBER 2R. Lift Truck Will Not Move In Either Direction. The Direction Contactors Never Close. The Regenerative Braking ....301 FAULT NUMBER 3R. Lift Truck Will Not Move In One Direction. The Regenerative Braking Contactor Closes Normally. Direction Cont....303 FAULT NUMBER 4R. Lift Truck Will Not Move In Either Direction. The Regenerative Braking Contactor Closes. A Direction Contacto....304 FAULT NUMBER 5R. Lift Truck Will Not Move In Either Direction. The Regenerative Braking Contactor Closes. The Direction Contac....306 FAULT NUMBER 6R. One Direction Contactor Will Not Close. The Regenerative Braking Contactor Closes Normally. The Traction Circ....308 FAULT NUMBER 7R. Direction Contactors Close Normally. The Lift Truck Has Only Low Power Or Moves Slowly. The Regenerative Brak....310 FAULT NUMBER 8R. Contactor 1a Will Not Energize. The Other Operations Of The Lift Truck Are Normal.................................311 FAULT NUMBER 9R. The Field Weakening Contactor Will Not Energize (36-48 Volt Lift Trucks Only). The Other Operations Of The Lif....312 FAULT NUMBER 10R. Regenerative Braking And Plugging Problems........................................................................313 FAULT NUMBER 11R. The Hydraulic Pump Will Not Operate When Any Hydraulic Hand Lever Is Moved From The Neutral Position..............314 FAULT NUMBER 12R. The Hydraulic Pump Will Not Stop Operating When The Hydraulic Hand Levers Are Returned To The Neutral Position....315 FAULT NUMBER 13R. The Hydraulic Pump Will Not Operate When Only One Hydraulic Lever Is Moved From The Neutral Position. The Ope....316 EV-100-200LX Motor Controller & Handset.........................................................................................................317 INTRODUCTION................................................................................................................................317 General.................................................................................................................................317 DESCRIPTION.................................................................................................................................317 Diagnostic Control Card.................................................................................................................317 Status Codes........................................................................................................................319 Hand Set................................................................................................................................319 Instrument Panel Display................................................................................................................320 Hourmeter Functions.................................................................................................................320 Battery Indicator Functions.........................................................................................................320 Control Card Connections................................................................................................................321 CHECKS AND ADJUSTMENTS......................................................................................................................327 General.................................................................................................................................327 Function Codes......................................................................................................................327 Connecting The Control Card For Bench Checks And Adjustments........................................................................328 Connecting The Hand Set To A Control Card Installed In A Lift Truck.................................................................329 Checking And Adjusting Function Settings................................................................................................329 General.............................................................................................................................329 How To Connect And Check Hand Set ..................................................................................................329 How To Check And Adjust Functions...................................................................................................329 Function Descriptions...............................................................................................................330 Traction Control Cards (EV-100/200 LXT-LX)..........................................................................................330 Pump Control Card (EV-100/200 LXP)..................................................................................................334 Dual Motor Traction Control Card (EV-100 LXM).......................................................................................335 Function Tables.........................................................................................................................338 REPAIRS.....................................................................................................................................351 General.................................................................................................................................351 Control Card Plugs......................................................................................................................351 TROUBLESHOOTING.............................................................................................................................352 General.................................................................................................................................352 EV-100ZX Motor Controller Description & Repair..................................................................................................387 EV-100ZXE SCR MOTOR CONTROLLER, Description, Adjustments, Troubleshooting, Repairs, and Theory..............................................387 GENERAL.................................................................................................................................387 Model Number Data For EV-100ZX Controller...........................................................................................388 REGISTER PARAMETERS.....................................................................................................................397 General.............................................................................................................................397 Function Members....................................................................................................................397 CONTROL CARD, CHECKS AND ADJUSTMENTS....................................................................................................397 HAND SET................................................................................................................................398 How To Check And Adjust The Registers...............................................................................................398 How To Scroll Through The Fault Codes And Clear Them................................................................................398 Checks And Adjustments On The Work Bench............................................................................................399 When The Hand Set Is Connected To A Control Card Installed In A Lift Truck..........................................................400 FUNCTION NUMBER DESCRIPTIONS............................................................................................................401 TRACTION CONTROL CARDS (LABEL LETTERS - ZH AND ZY)......................................................................................402 PUMP CONTROL CARD (LABEL LETTER ZP).....................................................................................................408 REGISTER PARAMETERS.....................................................................................................................412 TROUBLESHOOTING.........................................................................................................................412 Status Codes........................................................................................................................413 REGISTER MAPS...........................................................................................................................413 STATUS CODE CHARTS..........................................................................................................................422 REPAIRS.....................................................................................................................................454 FUSES...................................................................................................................................455 CHECK AN SCR............................................................................................................................455 THE SCR ASSEMBLY........................................................................................................................456 THERMAL PROTECTOR.......................................................................................................................456 REPLACE THE SCR 1 ASSEMBLY..............................................................................................................456 THE "OFF" CIRCUIT FOR SCR 1.............................................................................................................456 Check The Reactor Assembly..........................................................................................................456 Check Suppressors For SCR 2 And SCR 5...............................................................................................457 Check SCR 2 And SCR 5...............................................................................................................457 Replace SCR 2 And SCR 5.............................................................................................................457 Check Capacitor C1..................................................................................................................457 DIODES D3 AND D4........................................................................................................................457 Check The Diodes D3 And D4..........................................................................................................458 Replacement, Diodes D3 And D4.......................................................................................................458 MOTOR CURRENT SENSOR....................................................................................................................458 CONTACTORS..............................................................................................................................458 Contactor Repair....................................................................................................................459 CONTROL CARD............................................................................................................................460 CONTROL CARD PLUGS......................................................................................................................461 Brush Wear Indicators...............................................................................................................462 THEORY OF OPERATION.........................................................................................................................463 ELECTRONIC SPEED CONTROLS...............................................................................................................463 The Silicon Controlled Rectifier (SCR)..............................................................................................463 A Motor Circuit That Operates With Pulses...........................................................................................463 Traction Circuit....................................................................................................................465 Hydraulic Pump Motor................................................................................................................465 The SCR 1 "OFF" Circuit.............................................................................................................466 INDUCTION CURRENT FROM THE MOTOR........................................................................................................468 CONTROL CARDS...........................................................................................................................468 Pulse Monitor Trip (PMT) (Traction Circuit Only)....................................................................................468 SRO Circuit (Traction Circuit Only).................................................................................................469 SEQUENCE OF OPERATION...................................................................................................................470 Control Card Adjustments (Traction Circuit).........................................................................................470 Accelerator Control.................................................................................................................473 SCR CONTROL (HYDRAULIC PUMP MOTOR)......................................................................................................473 CONTACTORS..............................................................................................................................474 CIRCUIT PROTECTION......................................................................................................................475 Traction Circuit Fuse...............................................................................................................475 Current Limit.......................................................................................................................475 Thermal Protection..................................................................................................................475 Suppressors.........................................................................................................................475 TRUCK MANAGEMENT MODULE (TMM1)..........................................................................................................475 TABLE 8. Terminal And Plug Wire Connections For TMM1 Module.........................................................................476 DISPLAY PANELS..........................................................................................................................476 Display Panel.......................................................................................................................476 Basic Display.......................................................................................................................476 Performance Display.................................................................................................................478 Brush Wear Indicators...............................................................................................................481 EV-100ZX Motor Controller parameter Tables......................................................................................................482 EV-100ZX SCR MOTOR CONTROLLER, Parameter Tables.............................................................................................482 REGISTER PARAMETERS.....................................................................................................................482 General.............................................................................................................................482 Function Numbers....................................................................................................................483 CONTROL CARD, CHECKS AND ADJUSTMENTS....................................................................................................483 REGISTER PARAMETERS.....................................................................................................................483 TABLE 1. EV-100ZX Parameters - E/J2.00-3.20XM (E/J45-65XM) and N30XMH (36 to 48V)(Traction Card Type ZH With Regenerative Brakin....484 TABLE 2. EV-100ZX Parameters - E2.00-3.20XM (E45-65XM) and N30XMH (36 to 48V)(Traction Card Type ZY NO Regenerative Braking and ....487 TABLE 3. EV-100ZX Parameters - E/J2.00-3.20XM (72 to 80V)(Traction Card Type ZH with Regenerative Braking and Field Weakening.......490 TABLE 4. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V)(Traction Card Type ZY With Regenerative Braking And NO Field Weakening......493 TABLE 5. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V)(Low Energy Usage)(Traction Card Type ZY With 9-inch Motor, Regenerative.....496 TABLE 6. EV-100ZX Parameters - All Lift Trucks (36 to 48 volts)(Hydraulic Pump Card Type ZP)........................................499 TABLE 7. EV-100ZX Parameters - All Lift Trucks (72 to 80 volts)(Hydraulic Pump Card Type ZP)........................................502 EV-100ZX-T100 Troubleshooting & Adjustments.....................................................................................................505 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers....................................505 COMPUTER SYSTEM.........................................................................................................................505 Connect A PC To A Control Card......................................................................................................506 HYTECt SOFTWARE PROGRAM ................................................................................................................507 How To Start The Program............................................................................................................507 Selecting The Communications Port...................................................................................................508 Verification Of Controller and Lift Truck...........................................................................................508 Select The Lift Truck Series........................................................................................................509 Undefined Controller Card...........................................................................................................510 Controller Card Register Parameter List.............................................................................................510 How To Enter A New Parameter........................................................................................................511 How To Save A Changed Parameter File................................................................................................512 How To Load A Saved Parameter File..................................................................................................512 How To Return To Factory Default Settings...........................................................................................513 How To Save Changes To The Controller Card..........................................................................................514 How To View The Status Codes .......................................................................................................514 Saving The Status Code To Disk......................................................................................................515 Closing and Clearing The Status Code List...........................................................................................516 COMMUNICATIONS PROGRAM (MODEM)..........................................................................................................516 Requirements........................................................................................................................517 README File.........................................................................................................................518 GE Sentry Software......................................................................................................................518 Getting Started.....................................................................................................................518 Where To Get Help...................................................................................................................519 Hardware and Software Requirements..................................................................................................519 Installation of the GE SENTRY SOFTWARE..............................................................................................519 How To Start The GE SENTRY Program..................................................................................................519 How To Reset The MIN and MAX Display................................................................................................521 How To Exit The GE SENTRY Program...................................................................................................521 EV-200 Motor Controller Operation & Repair......................................................................................................522 INTRODUCTION................................................................................................................................522 GENERAL.................................................................................................................................522 SEQUENCE OF OPERATION.......................................................................................................................524 CHECKS AND REPAIRS..........................................................................................................................525 GENERAL.................................................................................................................................525 FUSES...................................................................................................................................525 THE CONTROL CARD PLUGS..................................................................................................................525 HOW TO CHECK AN SCR.....................................................................................................................526 The SCR 1 Assembly..................................................................................................................527 Thermal Protector...................................................................................................................527 Replace The SCR 1 Assembly..........................................................................................................527 THE "OFF" CIRCUIT FOR SCR 1.............................................................................................................527 Check The Transformer Assembly......................................................................................................528 Check Suppressors For SCR 2 and SCR 5...............................................................................................528 Check SCR 2 and SCR 5...............................................................................................................529 Replace The SCR 2 And SCR 5.........................................................................................................529 Check Capacitor C1, C2..............................................................................................................529 DIODES D3 and D4........................................................................................................................529 Check Diodes D3 and D4..............................................................................................................529 Replacement of Diodes D3 and D4.....................................................................................................529 MOTOR CURRENT SENSOR....................................................................................................................530 THE ELECTRONIC DRIVER MODULE............................................................................................................530 CONTACTORS..............................................................................................................................531 Contactor Repair........................................................................................................................532 Removing A Contactor Assembly.......................................................................................................532 Contactor Contacts..................................................................................................................532 Coil................................................................................................................................532 CHECK THE PMT CIRCUIT...................................................................................................................533 ADJUSTMENTS.................................................................................................................................533 CONTROL CARD ADJUSTMENTS................................................................................................................533 "CREEP" (Creep Speed)...............................................................................................................533 "C/A" (Controlled Acceleration).....................................................................................................533 "1A TIME" (1A Time).................................................................................................................534 Field Weakening.....................................................................................................................534 Regenerative Braking................................................................................................................536 "R.B. C/L"..........................................................................................................................536 "R.B. DO"...........................................................................................................................536 "PLUG" (Plugging)...................................................................................................................537 Ramp Start..........................................................................................................................537 Accelerator Control.................................................................................................................537 SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS.................................................................................................537 VOLTAGE ADJUSTMENTS, SCR CONTROL FOR HYDRAULIC PUMP.....................................................................................538 Frame...........................................................................................................................................543 FRAME.......................................................................................................................................543 GENERAL.................................................................................................................................543 DESCRIPTION.............................................................................................................................543 BATTERY SPECIFICATIONS......................................................................................................................545 REPAIRS.....................................................................................................................................548 OVERHEAD GUARD..........................................................................................................................548 Removal.............................................................................................................................548 Installation........................................................................................................................548 BATTERY RESTRAINT AND SEAT ASSEMBLY.....................................................................................................549 COUNTERWEIGHT...........................................................................................................................553 Removal.............................................................................................................................553 Installation........................................................................................................................553 TRACTION MOTOR..........................................................................................................................554 Removal.............................................................................................................................554 Installation........................................................................................................................555 HYDRAULIC TANK..........................................................................................................................556 Inspection..........................................................................................................................556 Repairs, Small Leaks................................................................................................................556 Repairs, Large Leaks................................................................................................................556 Cleaning............................................................................................................................556 Steam Method Of Cleaning............................................................................................................556 Chemical Solution Method Of Cleaning................................................................................................557 Additional Preparations For Repair..................................................................................................557 PAINTING INSTRUCTIONS...................................................................................................................557 LABEL PLACEMENT.........................................................................................................................558 Hydraulic System................................................................................................................................564 HYDRAULIC SYSTEM............................................................................................................................564 GENERAL.................................................................................................................................564 DESCRIPTION.............................................................................................................................564 Hydraulic System....................................................................................................................564 OPERATION...............................................................................................................................565 Hydraulic System....................................................................................................................565 Hydraulic Pump......................................................................................................................566 Steering Pump.......................................................................................................................567 REPAIRS.....................................................................................................................................567 HYDRAULIC PUMP..........................................................................................................................567 Removal.............................................................................................................................567 Seal Placement......................................................................................................................568 Installation........................................................................................................................569 CHECKS AND ADJUSTMENTS......................................................................................................................569 MAIN CONTROL VALVE......................................................................................................................569 Linkage And Switches................................................................................................................569 Relief Valve........................................................................................................................570 STEERING RELIEF VALVE ..................................................................................................................571 TROUBLESHOOTING.............................................................................................................................573 SPECIFICATIONS..............................................................................................................................574 Industrial Battery..............................................................................................................................575 INTRODUCTION................................................................................................................................575 GENERAL.................................................................................................................................575 LEAD-ACID BATTERIES.....................................................................................................................575 SPECIFIC GRAVITY........................................................................................................................576 CHEMICAL REACTION IN A CELL.............................................................................................................576 ELECTRICAL TERMS........................................................................................................................577 HOW TO SELECT THE BATTERY...............................................................................................................577 VOLTAGE OF A BATTERY....................................................................................................................577 THE BATTERY AS A COUNTERWEIGHT..........................................................................................................578 BATTERY RATINGS.........................................................................................................................578 Kilowatt-Hours......................................................................................................................579 BATTERY MAINTENANCE.........................................................................................................................579 SAFETY PROCEDURES.......................................................................................................................579 MAINTENCE RECORDS.......................................................................................................................580 THE NEW BATTERY.........................................................................................................................580 HOW TO CLEAN THE BATTERY................................................................................................................581 HOW TO ADD WATER........................................................................................................................581 THE HYDROMETER..........................................................................................................................582 BATTERY TEMPERATURE.....................................................................................................................582 CHARGING THE BATTERY....................................................................................................................583 Types Of Battery Charges............................................................................................................584 Methods Of Charging.................................................................................................................585 Troubleshooting The Charger.........................................................................................................585 How to Know When The Battery Is Fully Charged.......................................................................................586 WHERE TO CHARGE THE BATTERIES...........................................................................................................586 Equipment Needed....................................................................................................................586 BATTERY CONNECTORS......................................................................................................................587 BATTERY CARE............................................................................................................................587 Instrument Panel Indicators & Senders...........................................................................................................589 INTRODUCTION................................................................................................................................589 GENERAL.................................................................................................................................589 DESCRIPTION.................................................................................................................................589 GENERAL.................................................................................................................................589 STEERING COLUMN GAUGES, METERS AND INDICATORS...........................................................................................592 LED DISPLAY PANEL.......................................................................................................................592 Battery Discharge Indicators........................................................................................................592 Brush Wear Indicators...............................................................................................................593 Motor Temperature Indicators........................................................................................................594 "LX" SERIES DISPLAY PANEL...............................................................................................................595 Hourmeter Functions.................................................................................................................596 Battery Indicator Function..........................................................................................................596 Status Code Function................................................................................................................596 "ZX" SERIES DISPLAY PANELS..............................................................................................................596 Display Panel.......................................................................................................................597 Basic Display Panels................................................................................................................597 Performance Display.................................................................................................................599 Brush Wear Indicators...............................................................................................................602 CHECKS AND ADJUSTMENTS......................................................................................................................602 GENERAL.................................................................................................................................602 REPLACEMENT.................................................................................................................................603 GENERAL.................................................................................................................................603 METER REPLACEMENT.......................................................................................................................603 SENDER REPLACEMENT......................................................................................................................604 Fuel Level Sender...................................................................................................................604 Pressure And Temperature Sender.....................................................................................................604 I.T.W. DISPLAY PANEL....................................................................................................................605 Removal.............................................................................................................................605 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT...................................................................606 Removal.............................................................................................................................606 Replacing Display Panel Assembly....................................................................................................606 Indicator LEDs......................................................................................................................606 Battery Indicators..................................................................................................................606 Digital Display (Performance Disply Panel Only).....................................................................................606 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only).......................................606 Replacing Parts Of The Basic Display Panel..........................................................................................607 Replacing Parts Of The Performance Display Panel....................................................................................609 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT.......................................................................609 Removal And Replacement.............................................................................................................609 SPECIFICATIONS..............................................................................................................................610 TROUBLESHOOTING.............................................................................................................................611 Lift Cylinders..................................................................................................................................612 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST................................................................................................612 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................................612 LIFT CYLINDERS..............................................................................................................................615 GENERAL.................................................................................................................................615 DESCRIPTION.............................................................................................................................615 Lowering Control Valve..............................................................................................................615 Cylinders (General).................................................................................................................618 Cylinders (H520-620B,H700-800A).....................................................................................................620 Cylinders (H360-460B)...............................................................................................................621 Cylinders (Two-Speed)...............................................................................................................621 REPAIRS.....................................................................................................................................622 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..................................................................................622 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................................622 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.............................................................626 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.......................................................624 DISASSEMBLY.............................................................................................................................624 ASSEMBLY................................................................................................................................626 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...........................................................................................626 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................................626 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead....................................................626 CHEVRON PACKING.........................................................................................................................627 LIFT CYLINDERS FOR VISTA MASTS..............................................................................................................630 DESCRIPTION.............................................................................................................................630 Lowering Control Valve..............................................................................................................632 REMOVAL.................................................................................................................................633 DISASSEMBLY.............................................................................................................................633 ASSEMBLY................................................................................................................................633 INSTALLATION............................................................................................................................634 Main Lift Cylinders.................................................................................................................634 Free-Lift Cylinders.................................................................................................................634 CHECKS AND ADJUSTMENTS......................................................................................................................635 CHECK FOR LEAKS IN LIFT SYSTEM..........................................................................................................635 TROUBLESHOOTING.............................................................................................................................636 SPECIFICATIONS..............................................................................................................................637 Main Control Valve..............................................................................................................................638 INTRODUCTION................................................................................................................................638 GENERAL.................................................................................................................................638 DESCRIPTION.............................................................................................................................638 OPERATION...............................................................................................................................639 Lift Section........................................................................................................................640 Tilt Section........................................................................................................................640 Relief Valve........................................................................................................................642 SOLENOID VALVE FOR AUXILIARY FUNCTION...................................................................................................643 Operation...........................................................................................................................643 REPAIRS.....................................................................................................................................643 MAIN CONTROL VALVE......................................................................................................................643 Removal and Disassembly.............................................................................................................643 Cleaning and Inspection.............................................................................................................644 Assembly............................................................................................................................644 Installation........................................................................................................................644 SOLENOID VALVE FOR AUXILIARY FUNCTION...................................................................................................644 Removal and Disassembly.............................................................................................................644 Assembly and Installation...........................................................................................................646 CHECKS AND ADJUSTMENTS......................................................................................................................646 PRESSURE RELIEF VALVES..................................................................................................................646 Primary Relief Valve................................................................................................................646 Seconday Relief Valve...............................................................................................................647 CONTROL LEVER ARRANGEMENT...............................................................................................................647 TROUBLESHOOTING.............................................................................................................................650 SPECIFICATIONS..............................................................................................................................652 Periodic Maintenance............................................................................................................................653 INTRODUCTION................................................................................................................................653 GENERAL.................................................................................................................................653 HOW TO MOVE A DISABLED LIFT TRUCK.......................................................................................................653 How to Tow a Lift Truck.............................................................................................................653 HOW TO PUT A LIFT TRUCK ON BLOCKS ......................................................................................................654 How To Raise the Drive Tires........................................................................................................654 How To Raise the Steering Tires.....................................................................................................654 MAINTENANCE SCHEDULE........................................................................................................................655 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY...............................................................................................657 HOW TO MAKE CHECKS WITH KEY SWITCH OFF ................................................................................................657 Hydraulic System....................................................................................................................657 Battery.............................................................................................................................657 Battery Restraint System............................................................................................................658 Operator Restraint System...........................................................................................................659 Inspection Of The Mast, Forks And Lift Chains.......................................................................................659 Tires and Wheels....................................................................................................................661 Forks, Adjustment...................................................................................................................661 Forks, Removal And Installation.....................................................................................................661 SAFETY LABELS...........................................................................................................................662 HOW TO MAKE CHECKS WITH THE KEY SWITCH ON...............................................................................................662 Gauges and Horns....................................................................................................................662 Lift System Operation...............................................................................................................663 Service Brakes......................................................................................................................663 Parking Brake.......................................................................................................................663 Steering System.........................................................................................................................663 EVERY 350 HOURS OR TWO MONTHS...............................................................................................................664 HYDRAULIC TANK BREATHER.................................................................................................................664 STEERING TIE RODS, E/J1.25-1.75XL (E25-35XL) and J2.00-3.00XL (J40-60XL)................................................................664 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................664 WHEEL NUT TORQUES.......................................................................................................................664 STEERING AXLE SPINDLES, E/J2.00-3.00XL (E/J40-60XL) E3.50-5.50XL (E70-120XL)............................................................664 MAST....................................................................................................................................664 LIFT CHAINS.............................................................................................................................665 Check for Wear......................................................................................................................665 Lubrication.........................................................................................................................666 FORKS...................................................................................................................................666 BRAKE FLUID.............................................................................................................................666 OTHER LUBRICATION.......................................................................................................................666 SEAT BRAKE..............................................................................................................................666 ELECTRICAL INSPECTION...................................................................................................................666 Contactors..........................................................................................................................667 Motor Brushes.......................................................................................................................667 EVERY 2000 HOURS OR YEARLY..................................................................................................................670 HYDRAULIC SYSTEM........................................................................................................................670 Change the Filter for the Hydraulic Oil.............................................................................................670 Change the Hydraulic Oil............................................................................................................671 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................671 SERVICE BRAKES..........................................................................................................................671 CONTACTORS..............................................................................................................................672 WHEEL BEARINGS..........................................................................................................................672 Steer Wheels, Lubrication...........................................................................................................672 Drive Wheels, Lubrication ..........................................................................................................672 LIFT CHAINS.............................................................................................................................672 GENERAL PROCEDURES..........................................................................................................................673 HOW TO CHARGE THE BATTERY...............................................................................................................673 HOW TO CHANGE THE BATTERY...............................................................................................................674 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................................678 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................................679 Check the Lift Cylinders for Leaks..................................................................................................679 Check the Tilt Cylinders for Leaks..................................................................................................680 LIFT CHAIN ADJUSTMENTS..................................................................................................................680 HOW TO CHECK THE PMT CIRCUIT............................................................................................................680 WELDING REPAIRS.........................................................................................................................682 CHANGE THE OVERHEAD GUARD...............................................................................................................682 WHEELS AND TIRES............................................................................................................................682 GENERAL.................................................................................................................................682 SOLID RUBBER TIRES (PRESS-ON)...........................................................................................................683 How To Change A Solid Rubber Tire...................................................................................................683 Install The Wheels..................................................................................................................684 PNEUMATIC TIRES.........................................................................................................................684 Remove the Wheels From The Lift Truck...............................................................................................684 Remove The Tire From The Wheel .....................................................................................................684 Install The Wheel In The Tire.......................................................................................................686 Add Air To The Tires................................................................................................................687 Install The Wheels......................................................................................................................687 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES.......................................................................................688 Remove The Tire From The Wheel......................................................................................................688 Install The Tire On The Wheel.......................................................................................................689 SPECIFICATIONS..............................................................................................................................690 REFERENCE TABLE.............................................................................................................................691 SAE & Metric Fasteners..........................................................................................................................692 INTRODUCTION................................................................................................................................692 NOMENCLATURE, THREADS...................................................................................................................692 STRENGTH IDENTIFICATION.................................................................................................................693 TABLE 1. BOLTS AND SCREWS...................................................................................................................693 TABLE 2. STUDS AND NUTS.....................................................................................................................694 TABLE 3. TORQUE NUTS........................................................................................................................695 TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................................696 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................................697 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................................698 Steering Axle...................................................................................................................................701 STEERING AXLE...............................................................................................................................701 GENERAL.................................................................................................................................701 DESCRIPTION.............................................................................................................................701 REPAIRS.....................................................................................................................................702 STEERING AXLE, H3.50-5.50XL (H70-110XL) and S3.50-5.50XL (S70-120XL), E3.50-5.50XL (E70-120XL, E70-120XL3)..............................702 Removal.............................................................................................................................702 Installation........................................................................................................................702 STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360L)..................................................................703 Removal........................................................................................................................703 Installation....................................................................................................................704 WHEELS AND HUBS, ALL UNITS..........................................................................................................704 Removal and Disassembly.............................................................................................................704 Cleaning............................................................................................................................705 Assembly and Installation...........................................................................................................705 SPINDLES AND BEARINGS, ALL UNITS........................................................................................................705 Removal.............................................................................................................................705 Cleaning............................................................................................................................706 Assembly and Installation...........................................................................................................706 TIE RODS, ALL UNITS.....................................................................................................................706 Removal.............................................................................................................................706 Cleaning............................................................................................................................707 Installation........................................................................................................................707 STEERING CYLINDER.......................................................................................................................708 Removal and Disassembly.............................................................................................................708 Cleaning and Inspection.............................................................................................................708 Assembly and Installation...........................................................................................................708 TROUBLESHOOTING.............................................................................................................................709 Steering Control Unit (Ross HGF)................................................................................................................710 STEERING CONTROL UNIT.......................................................................................................................710 GENERAL.................................................................................................................................710 DESCRIPTION.............................................................................................................................710 Control Valve Section...............................................................................................................710 Metering Section....................................................................................................................710 DISASSEMBLY AND INSPECTION..............................................................................................................712 ASSEMBLY................................................................................................................................722 TROUBLESHOOTING.............................................................................................................................736 Steering System.................................................................................................................................737 STEERING SYSTEM.............................................................................................................................737 GENERAL.................................................................................................................................737 DESCRIPTION.............................................................................................................................739 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................740 Removal Of The Assembly Components..................................................................................................740 Installation Of The Assembly Components.............................................................................................744 POWER STEERING MOTOR AND PUMP...............................................................................................................745 DESCRIPTION.............................................................................................................................745 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)......................................745 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)...........................................................................745 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)........................................................................................746 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL).......................................................................................748 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)......................................................................................749 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]..........................................749 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)......................................................................................750 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)....................................................................................752 REPAIRS, POWER STEERING PUMP............................................................................................................753 Seal Replacement....................................................................................................................754 HYDRAULIC STEERING MOTOR....................................................................................................................754 DESCRIPTION.............................................................................................................................754 REPAIRS, HYDRAULIC STEERING MOTOR.......................................................................................................755 Removal ............................................................................................................................755 Disassembly.........................................................................................................................755 Cleaning And Inspection.............................................................................................................755 Assembly............................................................................................................................756 Installation, Hydraulic Steering Motor..............................................................................................757 CHECKS AND ADJUSTMENTS......................................................................................................................757 AIR IN THE STEERING SYSTEM..............................................................................................................757 CHECK STEERING PRESSURE.................................................................................................................757 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)...........................................................................758 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS...........................................................................................759 TROUBLESHOOTING.............................................................................................................................761 Tilt Cylinders..................................................................................................................................764 INTRODUCTION................................................................................................................................764 GENERAL.................................................................................................................................764 DESCRIPTION.............................................................................................................................764 REPAIRS.....................................................................................................................................764 REMOVAL.................................................................................................................................764 DISASSEMBLY.............................................................................................................................764 CLEANING................................................................................................................................764 ASSEMBLY................................................................................................................................764 Tilt Cylinders with O-Rings or Single Lip Seals.....................................................................................764 Tilt Cylinders for the XM and XMS Models............................................................................................765 Tilt Cylinders for H700 800A and Early Model H700 920B..............................................................................767 INSTALLATION............................................................................................................................767 Tilt Cylinders Using Chevron Packing................................................................................................768 CHECKS AND ADJUSTMENTS......................................................................................................................770 CHECK THE TILT CYLINDERS FOR LEAKS......................................................................................................770 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.................................................................................770 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS....................................................................................771 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS...................................................................................772 TROUBLESHOOTING.............................................................................................................................774 Vista Mast Description & Repair.................................................................................................................775 VISTA® MASTS................................................................................................................................775 GENERAL.................................................................................................................................775 DESCRIPTION AND OPERATION...............................................................................................................775 CARRIAGES...............................................................................................................................775 TWO-STAGE MAST WITH LIMITED FREE-LIFT...................................................................................................775 TWO-STAGE MAST WITH FULL FREE-LIFT MAST.................................................................................................776 THREE-STAGE MAST WITH FULL FREE-LIFT....................................................................................................777 REPAIRS.....................................................................................................................................779 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)...................................................................................779 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)...................................................................................780 FORKS...................................................................................................................................780 Forks, Removal And Installation.....................................................................................................780 CARRIAGE................................................................................................................................782 Removal.............................................................................................................................782 SIDE-SHIFT CARRIAGE (EARLIER DESIGNS)...................................................................................................783 Disassembly, Side Shift Carriage....................................................................................................783 Assembly, Side Shift Carriage.......................................................................................................783 Installation........................................................................................................................786 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGNS)............................................................................................786 Removal.............................................................................................................................786 Repairs.............................................................................................................................787 Installation........................................................................................................................788 WEIGHT OF MAST PARTS....................................................................................................................789 TWO-STAGE MAST WITH LIMITED FREE LIFT...................................................................................................789 Removal.............................................................................................................................789 Disassembly.........................................................................................................................789 Cleaning and Inspection.............................................................................................................791 Assembly............................................................................................................................791 Installation........................................................................................................................792 TWO-STAGE MAST WITH FULL FREE-LIFT......................................................................................................792 Removal.............................................................................................................................792 Disassembly.........................................................................................................................792 Cleaning and Inspection.............................................................................................................793 Assembly............................................................................................................................793 Installation........................................................................................................................794 THREE-STAGE MAST WITH FULL FREE LIFT....................................................................................................795 Removal.............................................................................................................................795 Disassembly.........................................................................................................................795 Cleaning and Inspection.............................................................................................................795 Assembly............................................................................................................................795 Installation........................................................................................................................797 CHECKS AND ADJUSTMENTS......................................................................................................................799 CHECK THE OPERATION OF THE MAST.........................................................................................................799 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................................799 Lift System.........................................................................................................................799 Tilt System.........................................................................................................................799 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.........................................................................800 LIFT CHAIN ADJUSTMENTS..............................................................................................................800 MAST ADJUSTMENTS....................................................................................................................801 CARRIAGE ADJUSTMENT.................................................................................................................802 TROUBLESHOOTING.....................................................................................................................803
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