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Hyster C210 (N30XMH) Service Manual – PDF DOWNLOAD
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Description
Hyster C210 (N30XMH) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C210 (N30XMH) Service Manual – PDF DOWNLOAD
Language : English
Pages : 555
Downloadable : Yes
File Type : PDF
Size: 15.3 MB
TABLE OF CONTENTS:
Hyster C210 (N30XMH) Service Manual – PDF DOWNLOAD
Attachment...................................................................................................................................... 1 INTRODUCTION................................................................................................................................ 1 GENERAL................................................................................................................................. 1 DESCRIPTION............................................................................................................................. 1 REPAIR...................................................................................................................................... 2 ATTACHMENT REMOVAL...................................................................................................................... 2 DISASSEMBLY............................................................................................................................. 3 Side Shift Cylinder And Carriage.................................................................................................... 3 Traverse Cylinder................................................................................................................... 4 Boom................................................................................................................................ 4 Rotary Actuator And Fork Carriage................................................................................................... 5 ASSEMBLY................................................................................................................................ 5 Side Shift / Traverse Installation.................................................................................................. 5 Boom................................................................................................................................ 6 Rotary Actuator And Fork Carriage................................................................................................... 7 CHECKS AND ADJUSTMENTS...................................................................................................................... 7 THRUST ROLLERS ON THE SIDE SHIFT CARRIAGE............................................................................................... 7 THRUST ROLLERS ON THE BOOM.............................................................................................................. 7 LOAD ROLLERS ON THE BOOM................................................................................................................ 7 TRAVERSE CHAIN ADJUSTMENT............................................................................................................... 8 TROUBLESHOOTING............................................................................................................................. 8 SPECIFICATIONS.......................................................................................................................... 9 TABLE 1. TORQUE SPECIFICATIONS FOR THE ATTACHMENT....................................................................................... 9 TABLE 2. CLEARANCES..................................................................................................................... 9 Brake System.................................................................................................................................... 10 INTRODUCTION................................................................................................................................ 10 GENERAL................................................................................................................................. 10 DESCRIPTION AND OPERATION............................................................................................................... 10 Service Brakes...................................................................................................................... 10 Master Cylinder..................................................................................................................... 10 Parking Brake....................................................................................................................... 12 SERVICE BRAKES.......................................................................................................................... 12 Removal And Disassembly............................................................................................................. 12 Cleaning............................................................................................................................ 14 Inspection.......................................................................................................................... 15 Assembly And Installation........................................................................................................... 15 Adjustments......................................................................................................................... 17 PARKING BRAKE........................................................................................................................... 17 Removal And Disassembly............................................................................................................. 17 Assembly And Installation........................................................................................................... 18 Adjust The Parking Brake............................................................................................................ 18 MASTER CYLINDER......................................................................................................................... 21 Removal............................................................................................................................. 21 Cleaning And Inspection............................................................................................................. 21 Repair.............................................................................................................................. 21 Installation........................................................................................................................ 21 SEAT BRAKE ASSEMBLY..................................................................................................................... 24 CHECKS AND ADJUSTMENTS...................................................................................................................... 25 ADJUST THE SERVICE BRAKES............................................................................................................... 25 ADJUST THE BRAKE PEDAL.................................................................................................................. 25 ADJUST THE MASTER CYLINDER.............................................................................................................. 25 REMOVE THE AIR FROM THE BRAKE SYSTEM.................................................................................................... 25 TEST THE "PARKING BRAKE NOT APPLIED" WARNING............................................................................................ 25 TROUBLESHOOTING............................................................................................................................. 26 TORQUE SPECIFICATIONS....................................................................................................................... 28 Capacities & Specification...................................................................................................................... 31 COUNTERWEIGHTS.............................................................................................................................. 31 HYDRAULIC SYSTEM............................................................................................................................ 31 WHEELS AND TIRES ........................................................................................................................... 32 BATTERY SPECIFICATIONS - E2.00-3.20XM (E45-65XM, E45-XM2, N30XMH, N30XMH2).................................................................. 32 BATTERY SPECIFICATIONS - J2.00-3.20XM (J40-65XM, J40-65XM2)................................................................................. 33 CAPACITIES.................................................................................................................................. 33 MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS................................................................................................. 33 E45-65XM MAST SPEEDS (36 or 48 Volt) Americas............................................................................................... 34 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 34 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 35 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 36 E40-65XM, E40-65XM2, N30XMH2 MAST SPEEDS (36 or 48 Volt) (3/99) Americas.................................................................... 37 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*................................................................................................ 37 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*................................................................................................ 38 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 39 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 39 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 40 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 41 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 42 CONTACTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.................................................................................. 42 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................................ 43 E2.00-3.20XM, E2.00-3.20XM2, MAST SPEEDS (72 or 80 Volt) (3/99) Europe...................................................................... 44 190 mm MOTOR & LARGE LIFT PUMP*......................................................................................................... 44 190 mm MOTOR & SMALL LIFT PUMP*......................................................................................................... 45 203 or 190 mm LONG STACK MOTOR & SMALL LIFT PUMP*....................................................................................... 46 J40-65XM MAST SPEEDS (36 or 48 Volt) Americas............................................................................................... 47 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 47 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 48 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 49 J40-65XM, J40-65XM2, MAST SPEEDS (36 or 48 Volt) (3/99) Americas............................................................................ 50 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*................................................................................................ 50 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*................................................................................................ 51 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 52 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................ 52 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 53 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*........................................................................ 54 CONT. OR TRANSISTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................ 55 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................................ 56 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) (3/99) Europe...................................................................................... 57 190 mm MOTOR & LARGE LIFT PUMP*......................................................................................................... 57 190 mm MOTOR & SMALL LIFT PUMP*......................................................................................................... 58 203 or 190 mm LONG STACK MOTOR & LARGE LIFT PUMP*....................................................................................... 59 TORQUE SPECIFICATIONS....................................................................................................................... 60 REFERENCE TABLE............................................................................................................................. 63 DC Motor Maintenance............................................................................................................................ 64 INTRODUCTION................................................................................................................................ 64 ELECTRIC MOTOR MAINTENANCE, GENERAL..................................................................................................... 64 BRUSH AND COMMUNICATOR INSPECTION....................................................................................................... 64 Hydraulic Pump Motor And Traction Motor............................................................................................. 64 Steering Pump Motor................................................................................................................. 66 BRUSH WEAR REPLACEMENT GUIDE................................................................................................................ 66 Commutator Problems..................................................................................................................... 68 BRUSH REPLACEMENTS...................................................................................................................... 70 DISASSEMBLY OF MOTORS................................................................................................................... 72 Traction Motor And Hydraulic Pump Motor............................................................................................. 72 Steering Pump Motor................................................................................................................. 78 ASSEMBLY OF MOTORS...................................................................................................................... 80 Traction Motor And Hydraulic Pump Motor ............................................................................................ 80 Steering Pump Motor................................................................................................................. 80 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS.......................................................................................... 80 TESTS FOR A DAMAGED FIELD AND ARMATURE.................................................................................................. 81 Test For An Open Circuit In The Armature............................................................................................ 81 Test For A Short-Circuit In One Armature Winding.................................................................................... 81 Test For A Short-Circuit To Armature Shaft.......................................................................................... 82 Test For An Open Circuit In A Field Coil............................................................................................ 82 Test For A Short-Circuit In A Field Coil............................................................................................ 82 Test For A Short-Circuit Between The Field And The Motor Case....................................................................... 83 Brush Holder Test................................................................................................................... 83 TROUBLESHOOTING............................................................................................................................. 83 Diagrams........................................................................................................................................ 85 FIGURE 1. SCHEMATIC - EV - 100ZX SCR CONTROL FOR TRACTION MOTOR............................................................................. 85 FIGURE 2. SCHEMATIC - EV - 100ZX SCR CONTROL FOR LIFT PUMP MOTOR............................................................................ 86 FIGURE 3. SCHEMATIC - CONTACTOR CONTROL FOR LIFT PUMP MOTOR................................................................................. 87 FIGURE 4. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................ 89 FIGURE 5. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................ 91 FIGURE 6. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................ 93 FIGURE 7. WIRING CONNECTIONS, CONTROLLER PANEL-TOPANEL, E2.00-3.20XM (E45-65XM) AND N30XMH.................................................. 94 FIGURE 8. WIRING CONNECTIONS, CONTROLLER PANEL-TO-PANEL, J2.00-3.20XM (J40-65XM)............................................................ 95 FIGURE 9. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM)........................................................................................... 97 FIGURE 10. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM).......................................................................................... 99 FIGURE 11. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM)..........................................................................................101 FIGURE 12. TRUCK WIRING HARNESSES AND CABLES, E2.00-3.20XM (E45-65XM) AND N30XMH............................................................102 FIGURE 13. TRUCK POWER CABLES, E2.00-3.20XM (E45-65XM) AND N30XMH...........................................................................103 FIGURE 14. EV - 100 ZX SCR TRACTION AND PUMP MOTOR CONTROLLERS, E2.00-3.20XM (E45-65XM) AND N30XMH..........................................104 FIGURE 15. EV - 100 ZX SCR TRACTION MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL, E2.00-3.20XM (E45-65XM)....................................105 FIGURE 16. EV - 100ZX SCR TRACTION MOTOR AND SCR PUMP MOTOR CONTROLLERS, E2.00-3.20XM (E45-65XM) AND N30XMH.................................106 FIGURE 17. EV - 100ZX SCR TRACTION MOTOR CONTROLLER WITH CONTACTOR CONTROL OF PUMP MOTOR, E2.00-3.20XM (E45-65XM)...........................107 FIGURE 18. EV - 100ZX CONTACTOR PANEL, E2.00-3.20XM (E45-65XM) AND N30XMH...................................................................108 FIGURE 19. CHASSIS AND HYDRAULIC LINKAGE, SWITCH WIRING DETAILS, E2.00-3.20XM (E45-65XM) AND N30XMH.........................................109 FIGURE 20. TRUCK WIRING HARNESSES AND CABLES, J2.00-3.20XM (J40-65XM).......................................................................110 FIGURE 21. TRUCK POWER CANLES, J2.00-3.20XM (J40-65XM)......................................................................................111 FIGURE 22. EV - 100 ZX SCR TRACTION AND PUMP MOTOR CONTROLLERS, J2.00-3.20XM (J40-65XM).....................................................112 FIGURE 23. EV - 100 ZX SCR TRACTION MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL, J2.00-3.20XM (J40-65XM)....................................113 FIGURE 24. EV - 100ZX SCR TRACTION MOTOR AND SCR PUMP MOTOR CONTROLLERS, J2.00-3.20XM (J40-65XM)............................................114 FIGURE 25. EV - 100ZX SCR TRACTION MOTOR CONTROLLER WITH CONTACTOR CONTROL OF PUMP MOTOR, J2.00-3.20XM (J40-65XM)...........................115 FIGURE 26. EV - 100ZX CONTACTOR PANEL, J2.00-3.20XM (J40-54XM)..............................................................................116 FIGURE 27. CHASSIS AND HYDRAULIC LINKAGE, SWITCH WIRING DETAILS, J2.00-3.20XM (J40-65XM)....................................................117 FIGURE 28. STEERING COLUMN WIRING DETAIL....................................................................................................118 FIGURE 29. DISPLAY PANELS AND PLUG CONNECTORS...............................................................................................119 FIGURE 30. DETAIL OF BATTEY CONNECTORS WITH +12 VOLT TAP....................................................................................120 FIGURE 31. LIGHTING SCHEMATIC (CHASSIS).....................................................................................................121 FIGURE 32. LIGHTING SCHEMATIC (REAR), E2.00-3.02XM (E45-65XM) AND N30XMH....................................................................122 FIGURE 33. LIGHTING SCHEMATIC (REAR), J2.00-3.02XM (J40-65XM)...............................................................................123 FIGURE 34. LIGHTING WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH......................................................................125 FIGURE 35. LIGHTING WIRING DIAGRAM, J2.00-3.02XM (J40-65XM).................................................................................127 Drive Axle Speed Reducer........................................................................................................................128 INTRODUCTION................................................................................................................................128 GENERAL.................................................................................................................................128 DESCRIPTION.............................................................................................................................128 REPAIRS.....................................................................................................................................130 REMOVAL OF THE DRIVE AXLE...............................................................................................................130 Disassembly of the Drive Axle.......................................................................................................131 Disassembly of the Transmission and Differential....................................................................................132 CLEANING................................................................................................................................134 INSPECTION..............................................................................................................................134 ASSEMBLY................................................................................................................................134 Assembly Of The Transmission And Differential.......................................................................................134 Assembly Of The Drive Axle..........................................................................................................140 INSTALLATION OF THE DRIVE AXLE ASSEMBLY.................................................................................................141 TROUBLESHOOTING.............................................................................................................................142 TORQUE SPECIFICATIONS.......................................................................................................................143 Electrical System...............................................................................................................................144 ELECTRICAL SYSTEM...........................................................................................................................144 GENERAL.................................................................................................................................144 "LX" SERIES DISPLAY PANEL...............................................................................................................145 Hourmeter Functions.................................................................................................................146 Battery Indicator Function..........................................................................................................146 Status Code Function................................................................................................................147 "ZX" SERIES DISPLAY PANELS..............................................................................................................147 Display Panel.......................................................................................................................147 Basic Display Panels................................................................................................................147 Performance Display.................................................................................................................149 Brush Wear Indicators...............................................................................................................152 SEM DISPLAY PANELS - FEATURES...........................................................................................................152 Description Of Common Features......................................................................................................153 LED SYMBOL INDICATORS...............................................................................................................153 LCD SCREEN..........................................................................................................................153 BATTERY DISCHARGE INDICATOR (BDI)...................................................................................................153 SERVICE REMINDER....................................................................................................................153 STATUS CODES........................................................................................................................153 HOURMETER...........................................................................................................................153 Additional Features Of Premium Display Panel .......................................................................................153 Descriptions Of Additional Features (Available With The Premium Display) ...........................................................154 LCD SCREEN..........................................................................................................................154 OPERATOR PASSWORDS..................................................................................................................154 DAILY CHECK LIST AND SERVICE ITEMS..................................................................................................154 PERFORMANCE MODELS..................................................................................................................154 STATUS CODE LISTS...................................................................................................................154 ADJUSTMENTS OF BDI..................................................................................................................155 SEM DISPLAY PANEL INDICATORS............................................................................................................155 All Indicator Symbols...............................................................................................................155 Hourmeter Indicator Symbol..........................................................................................................156 Wrench Indicator Symbol.............................................................................................................156 Battery Indicator Symbol............................................................................................................156 Battery State-Of-Charge (BDI).......................................................................................................156 Brake Fluid Too Low Symbol..........................................................................................................156 Parking Brake Symbol................................................................................................................156 Fasten Seat Belt Symbol.............................................................................................................156 LCD "Screen" (Standard Display Panel)...............................................................................................156 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM.................................................................................156 Alpha Numeric "Screen"..............................................................................................................156 "Star" Push Button..................................................................................................................157 Push Buttons #1 Through #5..........................................................................................................157 OTHER CONTROL COMPONENTS................................................................................................................157 REPLACEMENT.................................................................................................................................158 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"................................................................................................158 Replace The Display Panel Assembly..................................................................................................158 Replace The Key Switch..............................................................................................................159 Indicator LEDs......................................................................................................................159 Battery Indicators..................................................................................................................159 Digital Display (Performance Display Panel Only) ...................................................................................159 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only)........................................161 Replace Parts Of The Basic Display Panel ...........................................................................................161 Replace Parts Of The Performance Display Panel......................................................................................162 SEM DISPLAY PANEL.......................................................................................................................163 Removal And Replacement.............................................................................................................163 REPLACE MOTOR CONTROLLER (SR or SP).....................................................................................................163 OTHER CONTROL COMPONENTS................................................................................................................163 Start Swtich........................................................................................................................163 Brake Light Switch..................................................................................................................164 Seat Switch.........................................................................................................................165 Adjust The External Seat Switch.....................................................................................................166 Switch For Optional Seat Brake......................................................................................................166 Parking Brake Switch................................................................................................................166 Direction Switches (Monotrol Pedal)................................................................................................167 Direction Control Switches (Steering Column)........................................................................................168 Direction Control Switches, E70-120XL3 (Steering Column)............................................................................169 Brake Fluid Switch..................................................................................................................169 Brush Wear And Over Temperature Sensors.............................................................................................169 Rocker Switches For Lights .........................................................................................................170 Accelerator Position Sensor.........................................................................................................170 On-Demand Steering Components.......................................................................................................172 Lights, Converter, Relay And Reverse Alarm..........................................................................................174 Horn And Horn Buttons...............................................................................................................177 Hydraulic Pump Switches.............................................................................................................178 CHECKS AND ADJUSTMENTS......................................................................................................................178 GENERAL.................................................................................................................................178 CONTROL AND POWER FUSES - "LX" OR "ZX"..................................................................................................178 CONTROL AND POWER FUSES - SEM...........................................................................................................181 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"............................................................................184 THERMAL SENSORS - SEM...................................................................................................................184 ADJUST THE START SWITCH.................................................................................................................184 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3...................................................................185 Direction Switches (MONOTROL).......................................................................................................187 ADJUST THE BRAKE LIGHT SWITCH.......................................................................................................187 CHECK SEAT SWITCH...................................................................................................................187 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE...........................................................................................187 ADJUST THE PARKING BRAKE SWITCH.....................................................................................................188 DIRECTIONAL SWITCHES................................................................................................................188 DIRECTIONAL SWITCHES (STEERING COLUMN)..............................................................................................188 HYDRAULIC PUMP SWITCHES.............................................................................................................188 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT......................................................................................188 ADJUST THE ACCELERATOR POSITION SENSOR..............................................................................................189 EV-100ZX Motor Controller Description & Repair..................................................................................................191 EV-100ZXE SCR MOTOR CONTROLLER, Description, Adjustments, Troubleshooting, Repairs, and Theory..............................................191 GENERAL.................................................................................................................................191 Model Number Data For EV-100ZX Controller...........................................................................................192 REGISTER PARAMETERS.....................................................................................................................201 General.............................................................................................................................201 Function Members....................................................................................................................201 CONTROL CARD, CHECKS AND ADJUSTMENTS....................................................................................................201 HAND SET................................................................................................................................202 How To Check And Adjust The Registers...............................................................................................202 How To Scroll Through The Fault Codes And Clear Them................................................................................202 Checks And Adjustments On The Work Bench............................................................................................203 When The Hand Set Is Connected To A Control Card Installed In A Lift Truck..........................................................204 FUNCTION NUMBER DESCRIPTIONS............................................................................................................205 TRACTION CONTROL CARDS (LABEL LETTERS - ZH AND ZY)......................................................................................206 PUMP CONTROL CARD (LABEL LETTER ZP).....................................................................................................212 REGISTER PARAMETERS.....................................................................................................................216 TROUBLESHOOTING.........................................................................................................................216 Status Codes........................................................................................................................217 REGISTER MAPS...........................................................................................................................217 STATUS CODE CHARTS..........................................................................................................................226 REPAIRS.....................................................................................................................................258 FUSES...................................................................................................................................259 CHECK AN SCR............................................................................................................................259 THE SCR ASSEMBLY........................................................................................................................260 THERMAL PROTECTOR.......................................................................................................................260 REPLACE THE SCR 1 ASSEMBLY..............................................................................................................260 THE "OFF" CIRCUIT FOR SCR 1.............................................................................................................260 Check The Reactor Assembly..........................................................................................................260 Check Suppressors For SCR 2 And SCR 5...............................................................................................261 Check SCR 2 And SCR 5...............................................................................................................261 Replace SCR 2 And SCR 5.............................................................................................................261 Check Capacitor C1..................................................................................................................261 DIODES D3 AND D4........................................................................................................................261 Check The Diodes D3 And D4..........................................................................................................262 Replacement, Diodes D3 And D4.......................................................................................................262 MOTOR CURRENT SENSOR....................................................................................................................262 CONTACTORS..............................................................................................................................262 Contactor Repair....................................................................................................................263 CONTROL CARD............................................................................................................................264 CONTROL CARD PLUGS......................................................................................................................265 Brush Wear Indicators...............................................................................................................266 THEORY OF OPERATION.........................................................................................................................267 ELECTRONIC SPEED CONTROLS...............................................................................................................267 The Silicon Controlled Rectifier (SCR)..............................................................................................267 A Motor Circuit That Operates With Pulses...........................................................................................267 Traction Circuit....................................................................................................................269 Hydraulic Pump Motor................................................................................................................269 The SCR 1 "OFF" Circuit.............................................................................................................270 INDUCTION CURRENT FROM THE MOTOR........................................................................................................272 CONTROL CARDS...........................................................................................................................272 Pulse Monitor Trip (PMT) (Traction Circuit Only)....................................................................................272 SRO Circuit (Traction Circuit Only).................................................................................................273 SEQUENCE OF OPERATION...................................................................................................................274 Control Card Adjustments (Traction Circuit).........................................................................................274 Accelerator Control.................................................................................................................277 SCR CONTROL (HYDRAULIC PUMP MOTOR)......................................................................................................277 CONTACTORS..............................................................................................................................278 CIRCUIT PROTECTION......................................................................................................................279 Traction Circuit Fuse...............................................................................................................279 Current Limit.......................................................................................................................279 Thermal Protection..................................................................................................................279 Suppressors.........................................................................................................................279 TRUCK MANAGEMENT MODULE (TMM1)..........................................................................................................279 TABLE 8. Terminal And Plug Wire Connections For TMM1 Module.........................................................................280 DISPLAY PANELS..........................................................................................................................280 Display Panel.......................................................................................................................280 Basic Display.......................................................................................................................280 Performance Display.................................................................................................................282 Brush Wear Indicators...............................................................................................................285 EV-100ZX Motor Controller Parameter Tables......................................................................................................286 EV-100ZX SCR MOTOR CONTROLLER, Parameter Tables.............................................................................................286 REGISTER PARAMETERS.....................................................................................................................286 General.............................................................................................................................286 Function Numbers....................................................................................................................287 CONTROL CARD, CHECKS AND ADJUSTMENTS....................................................................................................287 REGISTER PARAMETERS.....................................................................................................................287 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....288 TABLE 2. EV-100ZX Parameters - E2.00-3.20XM (E45-65XM) and N30XMH (36 to 48V)(Traction Card Type ZY NO Regenerative Braking and ....291 TABLE 3. EV-100ZX Parameters - E/J2.00-3.20XM (72 to 80V)(Traction Card Type ZH with Regenerative Braking and Field Weakening.......294 TABLE 4. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V)(Traction Card Type ZY With Regenerative Braking And NO Field Weakening......297 TABLE 5. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V)(Low Energy Usage)(Traction Card Type ZY With 9-inch Motor, Regenerative.....300 TABLE 6. EV-100ZX Parameters - All Lift Trucks (36 to 48 volts)(Hydraulic Pump Card Type ZP)........................................303 TABLE 7. EV-100ZX Parameters - All Lift Trucks (72 to 80 volts)(Hydraulic Pump Card Type ZP)........................................306 EV-100ZX T100 Troubleshooting & Adjustments.....................................................................................................309 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers....................................309 COMPUTER SYSTEM.........................................................................................................................309 Connect A PC To A Control Card......................................................................................................310 HYTECt SOFTWARE PROGRAM ................................................................................................................311 How To Start The Program............................................................................................................311 Selecting The Communications Port...................................................................................................312 Verification Of Controller and Lift Truck...........................................................................................312 Select The Lift Truck Series........................................................................................................313 Undefined Controller Card...........................................................................................................314 Controller Card Register Parameter List.............................................................................................314 How To Enter A New Parameter........................................................................................................315 How To Save A Changed Parameter File................................................................................................316 How To Load A Saved Parameter File..................................................................................................316 How To Return To Factory Default Settings...........................................................................................317 How To Save Changes To The Controller Card..........................................................................................318 How To View The Status Codes .......................................................................................................318 Saving The Status Code To Disk......................................................................................................319 Closing and Clearing The Status Code List...........................................................................................320 COMMUNICATIONS PROGRAM (MODEM)..........................................................................................................320 Requirements........................................................................................................................321 README File.........................................................................................................................322 GE Sentry Software......................................................................................................................322 Getting Started.....................................................................................................................322 Where To Get Help...................................................................................................................323 Hardware and Software Requirements..................................................................................................323 Installation of the GE SENTRY SOFTWARE..............................................................................................323 How To Start The GE SENTRY Program..................................................................................................323 How To Reset The MIN and MAX Display................................................................................................325 How To Exit The GE SENTRY Program...................................................................................................325 Frame...........................................................................................................................................326 INTRODUCTION................................................................................................................................326 GENERAL.................................................................................................................................326 DESCRIPTION.............................................................................................................................326 Main Frame..........................................................................................................................326 Other Frame Weldments...............................................................................................................326 Battery Restraint/Hood Frame And Plate For Optional Seat Brake......................................................................328 Overhead Guard......................................................................................................................329 REPAIRS.....................................................................................................................................330 OVERHEAD GUARD..........................................................................................................................330 Removal.............................................................................................................................330 Installation........................................................................................................................330 BATTERY RESTRAINT AND SEAT ASSEMBLY.....................................................................................................330 COUNTERWEIGHT...........................................................................................................................331 Removal.............................................................................................................................331 Installation........................................................................................................................332 TRACTION MOTOR..........................................................................................................................332 Removal.............................................................................................................................332 Installation........................................................................................................................334 HYDRAULIC TANK..........................................................................................................................334 Inspection..........................................................................................................................334 Repairs, Small Leaks................................................................................................................334 Repairs, Large Leaks................................................................................................................335 Cleaning............................................................................................................................335 Steam Method Of Cleaning............................................................................................................335 Chemical Solution Method Of Cleaning................................................................................................335 Additional Preparations For Repair..................................................................................................336 PAINTING INSTRUCTIONS...................................................................................................................337 LABEL REPLACEMENT.......................................................................................................................338 Hydraulic System................................................................................................................................340 INTRODUCTION................................................................................................................................340 GENERAL.................................................................................................................................340 DESCRIPTION.............................................................................................................................341 Hydraulic System....................................................................................................................341 OPERATION...............................................................................................................................341 Hydraulic System....................................................................................................................341 Hydraulic Gear Pump.................................................................................................................342 Rotator Actuator Valve..............................................................................................................342 Steering Pump.......................................................................................................................345 REPAIRS.....................................................................................................................................349 HYDRAULIC TANK..........................................................................................................................349 E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal.....................................................................................349 J2.00-3.20XM (J40-65XM) Tank Removal................................................................................................349 Tank Inspection.....................................................................................................................349 Tank Repairs, Small Leaks...........................................................................................................350 Tank Repairs, Large Leaks ..........................................................................................................350 Tank Cleaning.......................................................................................................................350 Steam Method Of Cleaning Tank.......................................................................................................350 Chemical Solution Method Of Cleaning Tank...........................................................................................350 Additional Preparations For Tank repair.............................................................................................351 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation................................................................................351 J2.00-3.20XM (J40-65XM) Tank Installation...........................................................................................351 FILTER REPLACEMENT......................................................................................................................352 HYDRAULIC PUMP..........................................................................................................................352 Removing E1.50-3.20XM (E25-65XM) and N30XMH Hydraulic Pump..........................................................................352 Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump...................................................................................353 Pump Seal Replacement And Pump Assembly.............................................................................................353 Assemble Pump On The Motor..........................................................................................................355 Install The Hydraulic Pump And Motor Assembly [E1.50-3.20XM (E25-65XM) and N30XMH]..................................................356 Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly...................................................................356 MAIN CONTROL VALVE......................................................................................................................357 STEERING PUMP...........................................................................................................................357 Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N30XMH....................................................................357 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM)...............................................................................358 Pump Assembly And Installation......................................................................................................359 ROTARY ACTUATOR VALVE...................................................................................................................360 Disassembly, Cleaning and Inspection................................................................................................360 Assembly............................................................................................................................360 STEERING CONTROL UNIT...................................................................................................................360 Control Unit Removal................................................................................................................361 Control Unit Installation...........................................................................................................361 STEERING CYLINDER.......................................................................................................................361 CHECKS AND ADJUSTMENTS......................................................................................................................363 MAIN CONTROL VALVE......................................................................................................................363 STEERING RELIEF VALVE...................................................................................................................363 TROUBLESHOOTING CHART.......................................................................................................................363 SPECIFICATIONS..............................................................................................................................367 Industrial Battery..............................................................................................................................370 INTRODUCTION................................................................................................................................370 GENERAL.................................................................................................................................370 LEAD-ACID BATTERIES.....................................................................................................................370 SPECIFIC GRAVITY........................................................................................................................371 CHEMICAL REACTION IN A CELL.............................................................................................................371 ELECTRICAL TERMS........................................................................................................................372 HOW TO SELECT THE BATTERY...............................................................................................................372 VOLTAGE OF A BATTERY....................................................................................................................372 THE BATTERY AS A COUNTERWEIGHT..........................................................................................................373 BATTERY RATINGS.........................................................................................................................373 Kilowatt-Hours......................................................................................................................374 BATTERY MAINTENANCE.........................................................................................................................374 SAFETY PROCEDURES.......................................................................................................................374 MAINTENCE RECORDS.......................................................................................................................375 THE NEW BATTERY.........................................................................................................................375 HOW TO CLEAN THE BATTERY................................................................................................................376 HOW TO ADD WATER........................................................................................................................376 THE HYDROMETER..........................................................................................................................377 BATTERY TEMPERATURE.....................................................................................................................377 CHARGING THE BATTERY....................................................................................................................378 Types Of Battery Charges............................................................................................................379 Methods Of Charging.................................................................................................................380 Troubleshooting The Charger.........................................................................................................380 How to Know When The Battery Is Fully Charged.......................................................................................381 WHERE TO CHARGE THE BATTERIES...........................................................................................................381 Equipment Needed....................................................................................................................381 BATTERY CONNECTORS......................................................................................................................382 BATTERY CARE............................................................................................................................382 Instrument Cluster..............................................................................................................................384 INTRODUCTION................................................................................................................................384 GENERAL.................................................................................................................................384 DESCRIPTION.............................................................................................................................384 REPAIRS.....................................................................................................................................388 REMOVAL AND DISASSEMBLY.................................................................................................................388 ASSEMBLY AND INSTALLATION...............................................................................................................388 Lift Cylinders..................................................................................................................................391 INTRODUCTION................................................................................................................................391 GENERAL.................................................................................................................................391 DESCRIPTION.............................................................................................................................391 Lower Control Valve.................................................................................................................392 REPAIRS.....................................................................................................................................393 MAIN CYLINDER - DISASSEMBLY.............................................................................................................393 MAIN CYLINDER - ASSEMBLY................................................................................................................394 FREE-LIFT CYLINDER - DISASSEMBLY........................................................................................................395 FREE-LIFT CYLINDER - ASSEMBLY...........................................................................................................396 TROUBLESHOOTING.............................................................................................................................397 Main Control Valve..............................................................................................................................400 INTRODUCTION................................................................................................................................400 GENERAL.................................................................................................................................400 DESCRIPTION.............................................................................................................................400 OPERATION...............................................................................................................................401 Lift Section (See FIGURE 3.)............................................................................................................402 Auxiliary Section.......................................................................................................................402 Relief Valve (See FIGURE 5.)............................................................................................................403 REPAIRS.....................................................................................................................................404 MAIN CONTROL VALVE......................................................................................................................404 Removal (See FIGURE 8. And FIGURE 9.)...................................................................................................404 Disassembly (See FIGURE 6.).............................................................................................................405 Cleaning And Inspection.................................................................................................................405 Assembly (See FIGURE 6.)................................................................................................................405 Installation, (See FIGURE 7. And FIGURE 8.).............................................................................................405 CONTROL LEVER LINKAGE...................................................................................................................407 Removal (See FIGURE 9.).................................................................................................................407 Disassembly (See FIGURE 9.).............................................................................................................407 Assembly And Installation (See FIGURE 9.)...............................................................................................407 CONTROL VALVE LINKAGE...................................................................................................................410 Removal And Disassembly (See FIGURE 10.)................................................................................................410 Assembly And Installation (See FIGURE 10.)..............................................................................................410 CHECKS AND ADJUSTMENTS......................................................................................................................411 PRESSURE RELIEF VALVES..................................................................................................................411 Primary Relief Valve (See FIGURE 12.)...................................................................................................411 Secondary Relief Valve (See FIGURE 12.).................................................................................................412 TROUBLESHOOTING.............................................................................................................................412 TROUBLESHOOTING.............................................................................................................................413 Periodic Maintenance............................................................................................................................415 INTRODUCTION................................................................................................................................415 GENERAL.................................................................................................................................415 SERIAL NUMBER DATA......................................................................................................................415 HOW TO MOVE A DISABLED LIFT TRUCK.......................................................................................................415 How To Tow A Lift Truck.............................................................................................................415 HOW TO PUT A LIFT TRUCK ON BLOCKS.......................................................................................................416 How To Raise The Drive Tires........................................................................................................416 How To Raise The Steering Tires.....................................................................................................416 MAINTENANCE SCHEDULE........................................................................................................................417 MAINTENANCE PROCEDURES......................................................................................................................419 EVERY 8 HOURS OR DAILY......................................................................................................................419 HOW TO MAKE CHECKS WITH THE KEY OFF.....................................................................................................419 Tires And Wheels....................................................................................................................419 Forks...............................................................................................................................420 Fork Adjustment.....................................................................................................................420 Fork Removal........................................................................................................................420 Fork Installation...................................................................................................................420 Inspection Of Forks, Attachment, Mast, And Lift Chains..............................................................................420 Safety Labels.......................................................................................................................422 Steering Column Latch...............................................................................................................422 Operator Restraint System...........................................................................................................422 Battery Restraint System............................................................................................................422 Battery.............................................................................................................................423 Hydraulic System....................................................................................................................424 HOW TO MAKE CHECKS WITH THE KEY ON......................................................................................................424 Gauges, Horn And Fuses..............................................................................................................424 Steering System.....................................................................................................................424 Service Brakes......................................................................................................................424 Parking Brake.......................................................................................................................425 Control Levers And Pedals...........................................................................................................425 Lift System Operation...............................................................................................................425 EVERY 350 HOURS OR TWO MONTHS...............................................................................................................426 HYDRAULIC TANK BREATHER.................................................................................................................426 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................426 WHEEL NUT TORQUES.......................................................................................................................426 STEERING AXLE SPINDLES..................................................................................................................426 MAST....................................................................................................................................426 LIFT CHAINS.............................................................................................................................427 Check For Wear......................................................................................................................427 Lubrication.........................................................................................................................427 FORKS...................................................................................................................................427 BRAKE FLUID.............................................................................................................................428 OTHER LUBRICATION.......................................................................................................................428 SEAT BRAKE..............................................................................................................................428 ELECTRICAL INSPECTION...................................................................................................................428 CONTACTORS..........................................................................................................................429 MOTOR BRUSHES.......................................................................................................................429 Motor Brushes, General..............................................................................................................429 EVERY 2000 HOURS OR YEARLY..................................................................................................................434 HYDRAULIC SYSTEM........................................................................................................................434 Change The Filter For The Hydraulic Oil.............................................................................................434 Change The Hydraulic Oil............................................................................................................434 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................434 SERVICE BRAKES..........................................................................................................................434 CONTACTORS..............................................................................................................................435 WHEEL BEARINGS..........................................................................................................................435 Steering Wheels, Lubrication........................................................................................................435 Drive Wheels, Lubrication...........................................................................................................435 LIFT CHAINS.............................................................................................................................435 GENERAL PROCEDURES..........................................................................................................................436 HOW TO CHARGE THE BATTERY...............................................................................................................436 HOW TO CHARGE THE BATTERY...............................................................................................................437 General.............................................................................................................................437 Changing The Battery....................................................................................................................437 CHECK FOR LEAKS IN THE HYDRAULIC SYSTEM.................................................................................................439 Check The Cylinders For Leaks.......................................................................................................439 LIFT CHAIN ADJUSTMENTS..................................................................................................................439 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................................440 HOW TO CHECK THE PMT CIRCUIT............................................................................................................441 WELDING REPAIRS.........................................................................................................................442 CHANGES TO THE OVERHEAD GUARD...........................................................................................................442 TIRES AND WHEELS........................................................................................................................442 Removing Wheels From The Lift Truck.................................................................................................442 Remove And Install The Tire On The Wheel............................................................................................442 SAE & Metric Fasteners..........................................................................................................................445 INTRODUCTION................................................................................................................................445 NOMENCLATURE, THREADS...................................................................................................................445 STRENGTH IDENTIFICATION.................................................................................................................446 TABLE 1. BOLTS AND SCREWS...................................................................................................................446 TABLE 2. STUDS AND NUTS.....................................................................................................................447 TABLE 3. TORQUE NUTS........................................................................................................................448 TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................................449 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................................450 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................................451 Steer Axle......................................................................................................................................454 INTRODUCTION................................................................................................................................454 GENERAL.................................................................................................................................454 DESCRIPTION.............................................................................................................................454 REPAIRS.....................................................................................................................................455 STEERING AXLE ASSEMBLY..................................................................................................................455 Removal.............................................................................................................................455 Installation........................................................................................................................455 WHEELS..................................................................................................................................455 Removal And Disassembly.............................................................................................................455 Cleaning............................................................................................................................455 Assembly And Installation...........................................................................................................456 SPINDLES, BEARINGS, AND TIE RODS........................................................................................................456 Removal And Disassembly.............................................................................................................456 Assembly And Installation...........................................................................................................457 STEERING CYLINDER.......................................................................................................................458 Removal And Disassembly.............................................................................................................458 Cleaning And Inspection.............................................................................................................458 Assembly And Installation...........................................................................................................458 TROUBLESHOOTING.............................................................................................................................459 TORQUE SPECIFICATIONS.......................................................................................................................459 Steering Housing & Control Unit.................................................................................................................461 INTRODUCTION................................................................................................................................461 GENERAL.................................................................................................................................461 DESCRIPTION.............................................................................................................................461 OPERATION...............................................................................................................................461 REPAIRS.....................................................................................................................................462 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................462 Removal of the Assembly Components..................................................................................................466 Disassembly of the Steering Control Unit............................................................................................467 Cleaning of the Steering Control Unit...............................................................................................467 Assembly of the Steering Control Unit...............................................................................................467 Installation of the Steering Control Unit...........................................................................................467 Installation of the Assembly Components.............................................................................................467 CHECKS AND ADJUSTMENTS......................................................................................................................475 REMOVE AIR FROM THE SYSTEM..............................................................................................................475 TROUBLESHOOTING.............................................................................................................................475 Steering System.................................................................................................................................477 STEERING SYSTEM.............................................................................................................................477 GENERAL.................................................................................................................................477 DESCRIPTION.............................................................................................................................479 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................480 Removal Of The Assembly Components..................................................................................................480 Installation Of The Assembly Components.............................................................................................484 POWER STEERING MOTOR AND PUMP...............................................................................................................485 DESCRIPTION.............................................................................................................................485 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)......................................485 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)...........................................................................485 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)........................................................................................486 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL).......................................................................................488 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)......................................................................................489 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]..........................................489 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)......................................................................................490 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)....................................................................................492 REPAIRS, POWER STEERING PUMP............................................................................................................493 Seal Replacement....................................................................................................................494 HYDRAULIC STEERING MOTOR....................................................................................................................494 DESCRIPTION.............................................................................................................................494 REPAIRS, HYDRAULIC STEERING MOTOR.......................................................................................................495 Removal ............................................................................................................................495 Disassembly.........................................................................................................................495 Cleaning And Inspection.............................................................................................................495 Assembly............................................................................................................................496 Installation, Hydraulic Steering Motor..............................................................................................497 CHECKS AND ADJUSTMENTS......................................................................................................................497 AIR IN THE STEERING SYSTEM..............................................................................................................497 CHECK STEERING PRESSURE.................................................................................................................497 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)...........................................................................498 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS...........................................................................................499 TROUBLESHOOTING.............................................................................................................................501 Vista Mast Description..........................................................................................................................504 INTRODUCTION................................................................................................................................504 GENERAL.................................................................................................................................504 MAST WELDMENTS..........................................................................................................................505 CARRIAGES...............................................................................................................................506 VISTA TWO-STAGE MAST........................................................................................................................506 DESCRIPTION.............................................................................................................................506 OPERATION...............................................................................................................................508 VISTA THREE-STAGE MAST......................................................................................................................509 DESCRIPTION.............................................................................................................................509 OPERATION...............................................................................................................................511 Vista Mast Repair...............................................................................................................................516 INTRODUCTION................................................................................................................................516 General.................................................................................................................................516 SAFETY PROCEDURES...........................................................................................................................516 LOAD BACKREST EXTENSION, CARRIAGE, LOAD ROLLERS, SIDE ROLLERS AND FORKS.....................................................................517 Load Backrest Extension - Removal And Installation......................................................................................517 Carriage Assembly - Removal And Installation............................................................................................518 Carriage Load Rollers - Removal And Installation........................................................................................520 Side Rollers - Disassembly And Assembly.................................................................................................521 Fork Replacement........................................................................................................................521 Forks - Carriage....................................................................................................................521 Forks - Reach Carriage..............................................................................................................522 TWO-STAGE MAST ASSEMBLY.....................................................................................................................522 Two-Stage Mast Assembly - Removal.......................................................................................................522 Cleaning And Inspection.................................................................................................................523 Lift Cylinders - Removal And Installation...............................................................................................525 Inner Mast Assembly - Removal And Installation..........................................................................................527 Hoses - Replace.........................................................................................................................527 Hoses And Cable Sheaves - Replace.......................................................................................................527 Two-Stage Lift Chains...................................................................................................................528 Removal And Installation............................................................................................................528 Cleaning And Inspection.............................................................................................................528 Two-Stage Chain Sheave - Removal And Installation.......................................................................................528 Load Rollers And Wear Plugs - Removal And Installation..................................................................................529 Two-Stage Mast Assembly - Installation..................................................................................................530 THREE-STAGE MAST ASSEMBLY...................................................................................................................531 Three-Stage Mast Assembly - Removal.....................................................................................................531 Cleaning And Inspection.................................................................................................................532 Free-Lift Cylinder - Removal And Installation...........................................................................................534 Inner And Intermediate Mast Assemblies - Removal And Installation.......................................................................537 Hoses - Replace.........................................................................................................................538 Hose And Cable Sheaves - Replace........................................................................................................538 Free-Lift Hose Sheave...............................................................................................................540 Carriage Sheaves....................................................................................................................540 Three-Stage Lift Chains - Removal And Installation......................................................................................540 General.............................................................................................................................540 Free-Lift Chains....................................................................................................................540 Main-Lift Chains....................................................................................................................541 Three-Stage Chain Sheaves - Diassembly And Assembly.....................................................................................541 Free-Lift Chain Sheaves.............................................................................................................541 Main-Lift Chain Sheaves.............................................................................................................541 Load Rollers And Wear Plugs - Removal And Installation..................................................................................542 Three-Stage Mast Assembly - Installation................................................................................................543 CHECKS AND ADJUSTMENTS......................................................................................................................544 Check The Operation Of The Mast.........................................................................................................544 Check For Leaks In The Hydraulic System.................................................................................................544 Check Lift Chains.......................................................................................................................545 General.............................................................................................................................545 Cleaning And Inspection.............................................................................................................545 Lubrication.........................................................................................................................545 Mast Adjustments........................................................................................................................546 General.............................................................................................................................546 Adjust Wear Plugs - Mast............................................................................................................546 Adjust Free-Lift Chains (Three-Stage Only)..........................................................................................547 Adjust Main-Lift Chains.............................................................................................................548 Adjust Wear Strips..................................................................................................................549 Carriage Adjustments....................................................................................................................550 Adjust Wear Plugs - Carriage........................................................................................................550 Adjust Side Rollers - Carriage......................................................................................................551 Adjust Thrust Rollers - Carriage....................................................................................................551
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