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Hyster D114 (E25-35XM₂, E40XMS₂) Service Manual – PDF DOWNLOAD
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Hyster D114 (E25-35XM₂, E40XMS₂) Service Manual – PDF DOWNLOAD
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Description
Hyster D114 (E25-35XM₂, E40XMS₂) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster D114 (E25-35XM₂, E40XMS₂) Service Manual – PDF DOWNLOAD
Language : English
Pages : 590
Downloadable : Yes
File Type : PDF
Size: 16.4 MB
TABLE OF CONTENTS:
Hyster D114 (E25-35XM₂, E40XMS₂) Service Manual – PDF DOWNLOAD
Brake System................................................................................................................................ 1 INTRODUCTION............................................................................................................................ 1 BRAKE SYSTEM, GENERAL............................................................................................................... 1 DESCRIPTION AND OPERATION........................................................................................................... 1 Service Brakes.................................................................................................................. 1 Master Cylinder................................................................................................................. 1 Parking Brake................................................................................................................... 1 SERVICE BRAKES...................................................................................................................... 3 Removal And Disassembly......................................................................................................... 3 Cleaning........................................................................................................................ 4 Inspection...................................................................................................................... 5 Assembly And Installation....................................................................................................... 5 MASTER CYLINDER..................................................................................................................... 8 Removal......................................................................................................................... 8 Cleaning And Inspection......................................................................................................... 8 Repair.......................................................................................................................... 8 Installation.................................................................................................................... 8 PARKING BRAKE....................................................................................................................... 10 Removal And Disassembly......................................................................................................... 10 Assembly And Installation....................................................................................................... 11 REPLACE THE PARKING BRAKE SWITCH.................................................................................................... 12 CHECKS AND ADJUSTMENTS.............................................................................................................. 13 Remove The Air From The Brake System............................................................................................ 13 Adjust The Service Brakes....................................................................................................... 13 Adjust The Brake Pedal.......................................................................................................... 14 Adjust The Master Cylinder...................................................................................................... 14 Adjust The Parking Brake........................................................................................................ 14 Adjust The Parking Brake Switch................................................................................................. 14 Test The "Parking Brake Not Applied" Warning.................................................................................... 14 Adjust The Seat Brake........................................................................................................... 14 TORQUE SPECIFICATIONS................................................................................................................... 16 TROUBLESHOOTING......................................................................................................................... 16 Capacities & Specification.................................................................................................................. 19 WHEELS AND TIRES ....................................................................................................................... 19 COUNTERWEIGHTS.......................................................................................................................... 19 HYDRAULIC SYSTEM........................................................................................................................ 19 CAPACITIES.............................................................................................................................. 19 BATTERY SPECIFICATIONS.................................................................................................................. 20 BATTERY HEIGHT SPECIFICATIONS (Hoods and Battery Types)................................................................................. 20 MAXIMUM CARRIAGE AND TILT CREEP RATES................................................................................................... 21 E25-40XM MAST SPEEDS (36 & 48 VOLT) Americas............................................................................................ 21 CONTACTOR CONTROLLED 184 mm (7.25 in) MOTOR & 19 cc (1.16 in3) LIFT PUMP*........................................................... 21 TRAN. OR SCR CONTROLLED 184 mm (7.25 in) MOTOR & 19 cc (1.16 in3) LIFT PUMP*........................................................ 22 CONTACTOR CONTROLLED 184 mm (7.25 in) MOTOR & 12 cc (0.73 in3) LIFT PUMP............................................................ 23 CONTACTOR CONTROLLED 169 mm (6.65 in) MOTOR & 12 cc (0.73 in3) LIFT PUMP*........................................................... 24 E1.50-2.00XM MAST SPEEDS (48 VOLT) Europe............................................................................................... 25 CONTACTOR CONTROLLED 184 mm MOTOR & 19 cc LIFT PUMP*................................................................................ 25 CONTACTOR CONTROLLED 169 mm MOTOR & 12 cc LIFT PUMP*................................................................................ 26 TRANSISTOR CONTROLLED 184 mm MOTOR & 19 cc LIFT PUMP*............................................................................... 27 TRANSISTOR CONTROLLED 169 mm MOTOR & 12 cc LIFT PUMP*............................................................................... 28 E25-40XM, E25-40XM2 MAST SPEEDS (3/99) Americas......................................................................................... 29 184 mm (7.25 in) MOTOR & 19 cc (1.16 in3) LIFT PUMP*................................................................................ 29 184 mm (7.25 in) MOTOR & 12 cc (0.73 in3) LIFT PUMP*................................................................................ 30 169 mm (6.65 in) MOTOR & 12 cc (0.73 in3) LIFT PUMP*................................................................................ 31 E1.50-1.75XM E2.00XMS MAST SPEEDS (3/99) Europe......................................................................................... 32 184 mm MOTOR & 19 cc LIFT PUMP*..................................................................................................... 32 169 mm MOTOR & 12 cc LIFT PUMP*..................................................................................................... 33 TORQUE SPECIFICATIONS................................................................................................................... 33 REFERENCE TABLE......................................................................................................................... 35 DC Motor Maintenance........................................................................................................................ 36 INTRODUCTION............................................................................................................................ 36 ELECTRIC MOTOR MAINTENANCE, GENERAL................................................................................................. 36 BRUSH AND COMMUNICATOR INSPECTION................................................................................................... 36 Hydraulic Pump Motor And Traction Motor......................................................................................... 36 Steering Pump Motor............................................................................................................. 38 BRUSH WEAR REPLACEMENT GUIDE............................................................................................................ 38 Commutator Problems................................................................................................................. 40 BRUSH REPLACEMENTS.................................................................................................................. 42 DISASSEMBLY OF MOTORS............................................................................................................... 44 Traction Motor And Hydraulic Pump Motor......................................................................................... 44 Steering Pump Motor............................................................................................................. 50 ASSEMBLY OF MOTORS.................................................................................................................. 52 Traction Motor And Hydraulic Pump Motor ........................................................................................ 52 Steering Pump Motor............................................................................................................. 52 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS...................................................................................... 52 TESTS FOR A DAMAGED FIELD AND ARMATURE.............................................................................................. 53 Test For An Open Circuit In The Armature........................................................................................ 53 Test For A Short-Circuit In One Armature Winding................................................................................ 53 Test For A Short-Circuit To Armature Shaft...................................................................................... 54 Test For An Open Circuit In A Field Coil........................................................................................ 54 Test For A Short-Circuit In A Field Coil........................................................................................ 54 Test For A Short-Circuit Between The Field And The Motor Case................................................................... 55 Brush Holder Test............................................................................................................... 55 TROUBLESHOOTING......................................................................................................................... 55 Diagrams.................................................................................................................................... 57 FIGURE 1. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (E25-65XM2).................................................. 57 FIGURE 2. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (E25-65XM2)............................................................ 58 FIGURE 3. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (E25-65XM2).............................................................. 59 FIGURE 4. WIRING DIAGRAM - COMMON CONCEPTS (E25-65XM2) (SEM)............................................................................ 60 FIGURE 5. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLER (E25-65XM2)................................................................. 61 FIGURE 6. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (E25-65XM2)................................... 62 FIGURE 7. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (N30XMH2).................................................... 63 FIGURE 8. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (N30XMH2).............................................................. 64 FIGURE 9. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (N30XMH2)................................................................ 65 FIGURE 10. WIRING DIAGRAM - COMMON COMPONENTS (N30XMH2)................................................................................. 66 FIGURE 11. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLERS (N30XMH2)................................................................. 67 FIGURE 12. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (N30XMH2).................................... 68 FIGURE 13. ELECTRICAL WIRING CONNECTORS (E25-65XM2) (N30XMH2)........................................................................... 69 FIGURE 14. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (J40-65XM2)................................................. 70 FIGURE 15. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (J40-65XM2)........................................................... 71 FIGURE 16. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (J40-65XM2)............................................................. 72 FIGURE 17. WIRING DIAGRAM - COMMON COMPONENTS (J40-65XM2)............................................................................... 73 FIGURE 18. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLER (J40-65XM2)................................................................ 74 FIGURE 19. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (J40-65XM2).................................. 75 FIGURE 20. ELECTRICAL WIRING CONNECTORS (J40-65XM2)..................................................................................... 76 FIGURE 21. STEERING COLUMN WIRING DETAIL (E25-40XM2).................................................................................... 77 FIGURE 22. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS (E25-40XM2).............................................................. 78 FIGURE 23. TRUCK WIRING (E25-40XM2)..................................................................................................... 79 FIGURE 24. TRUCK POWER CABLES (E25-40XM2)............................................................................................... 80 FIGURE 25. STEERING COLUMN WIRING DETAIL (E40-65XM2, J40-65XM2 AND N30XMH2)............................................................. 81 FIGURE 26. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS (E40-65XM2, J40-65XM2 AND N30XMH2)....................................... 82 FIGURE 27. TRUCK WIRING (E40-65XM2, J40-65XM2 AND N30XMH2).............................................................................. 83 FIGURE 28. TRUCK POWER CABLES (E40-65XM2, J40-65XM2 AND N30XMH2)........................................................................ 84 FIGURE 29. PANEL WIRING WITH SR (SEM) AND SP MOTOR CONTROLLERS.......................................................................... 85 FIGURE 30. PANEL WIRING WITH SR (SEM) MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL....................................................... 86 FIGURE 31. SR (SEM) AND SP MOTOR CONTROLLERS............................................................................................ 87 FIGURE 32. SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL OF PUMP MOTOR................................................................ 88 FIGURE 33. (SEM) DISPLAY PANELS......................................................................................................... 89 FIGURE 34. (SEM) DISPLAY PANEL CONNECTIONS AND MOUNTING................................................................................. 90 FIGURE 35. LIGHTING SCHEMATIC DIAGRAM (E25-65XM2, J40-65XM2 AND N30XMH2)................................................................ 91 FIGURE 36. LIGHT WIRING DIAGRAM (E25-40XM2)............................................................................................. 93 FIGURE 37. LIGHT WIRING DIAGRAM (E45-65XM2 AND N30XMH2)................................................................................. 95 Drive Axle SPD Reducer & Differential....................................................................................................... 98 INTRODUCTION............................................................................................................................ 98 GENERAL............................................................................................................................. 98 DESCRIPTION......................................................................................................................... 98 REPAIRS................................................................................................................................. 98 DRIVE UNIT ASSEMBLY................................................................................................................. 98 Remove The Complete Drive Unit Assembly As A Unit............................................................................... 98 Traction Motor, Removal......................................................................................................... 99 Drive Unit And Speed Reducer, Removal...........................................................................................100 Disassembly Of The Drive Axle...................................................................................................101 Disassembly Of The Differential And Speed Reducer...............................................................................102 Cleaning........................................................................................................................103 Inspection......................................................................................................................103 ASSEMBLY OF THE DRIVE UNIT..........................................................................................................103 Find The Correct Shim Set For The Hypoid Gear...................................................................................103 Assembly And Installation Of Pinion.............................................................................................104 Assembly Of The Differential And Ring Gear......................................................................................105 Input Gear For The Speed Reducer, Assembly......................................................................................109 Drive Axle And Hub Assembly, Assembly...........................................................................................109 INSTALLATION OF DRIVE UNIT..........................................................................................................110 Drive Unit, Installation........................................................................................................110 Traction Motor, Installation....................................................................................................111 TORQUE SPECIFICATIONS...................................................................................................................112 TROUBLESHOOTING.........................................................................................................................112 Electrical System...........................................................................................................................113 ELECTRICAL SYSTEM.......................................................................................................................113 GENERAL.............................................................................................................................113 "LX" SERIES DISPLAY PANEL...........................................................................................................114 Hourmeter Functions.............................................................................................................115 Battery Indicator Function......................................................................................................115 Status Code Function............................................................................................................116 "ZX" SERIES DISPLAY PANELS..........................................................................................................116 Display Panel...................................................................................................................116 Basic Display Panels............................................................................................................116 Performance Display.............................................................................................................118 Brush Wear Indicators...........................................................................................................121 SEM DISPLAY PANELS - FEATURES.......................................................................................................121 Description Of Common Features..................................................................................................122 LED SYMBOL INDICATORS...........................................................................................................122 LCD SCREEN......................................................................................................................122 BATTERY DISCHARGE INDICATOR (BDI)...............................................................................................122 SERVICE REMINDER................................................................................................................122 STATUS CODES....................................................................................................................122 HOURMETER.......................................................................................................................122 Additional Features Of Premium Display Panel ...................................................................................122 Descriptions Of Additional Features (Available With The Premium Display) .......................................................123 LCD SCREEN......................................................................................................................123 OPERATOR PASSWORDS..............................................................................................................123 DAILY CHECK LIST AND SERVICE ITEMS..............................................................................................123 PERFORMANCE MODELS..............................................................................................................123 STATUS CODE LISTS...............................................................................................................123 ADJUSTMENTS OF BDI..............................................................................................................124 SEM DISPLAY PANEL INDICATORS........................................................................................................124 All Indicator Symbols...........................................................................................................124 Hourmeter Indicator Symbol......................................................................................................125 Wrench Indicator Symbol.........................................................................................................125 Battery Indicator Symbol........................................................................................................125 Battery State-Of-Charge (BDI)...................................................................................................125 Brake Fluid Too Low Symbol......................................................................................................125 Parking Brake Symbol............................................................................................................125 Fasten Seat Belt Symbol.........................................................................................................125 LCD "Screen" (Standard Display Panel)...........................................................................................125 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM.............................................................................125 Alpha Numeric "Screen"..........................................................................................................125 "Star" Push Button..............................................................................................................126 Push Buttons #1 Through #5......................................................................................................126 OTHER CONTROL COMPONENTS............................................................................................................126 REPLACEMENT.............................................................................................................................127 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"............................................................................................127 Replace The Display Panel Assembly..............................................................................................127 Replace The Key Switch..........................................................................................................128 Indicator LEDs..................................................................................................................128 Battery Indicators..............................................................................................................128 Digital Display (Performance Display Panel Only) ...............................................................................128 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only)....................................130 Replace Parts Of The Basic Display Panel .......................................................................................130 Replace Parts Of The Performance Display Panel..................................................................................131 SEM DISPLAY PANEL...................................................................................................................132 Removal And Replacement.........................................................................................................132 REPLACE MOTOR CONTROLLER (SR or SP).................................................................................................132 OTHER CONTROL COMPONENTS............................................................................................................132 Start Swtich....................................................................................................................132 Brake Light Switch..............................................................................................................133 Seat Switch.....................................................................................................................134 Adjust The External Seat Switch.................................................................................................135 Switch For Optional Seat Brake..................................................................................................135 Parking Brake Switch............................................................................................................135 Direction Switches (Monotrol Pedal)............................................................................................136 Direction Control Switches (Steering Column)....................................................................................137 Direction Control Switches, E70-120XL3 (Steering Column)........................................................................138 Brake Fluid Switch..............................................................................................................138 Brush Wear And Over Temperature Sensors.........................................................................................138 Rocker Switches For Lights .....................................................................................................139 Accelerator Position Sensor.....................................................................................................139 On-Demand Steering Components...................................................................................................141 Lights, Converter, Relay And Reverse Alarm......................................................................................143 Horn And Horn Buttons...........................................................................................................146 Hydraulic Pump Switches.........................................................................................................147 CHECKS AND ADJUSTMENTS..................................................................................................................147 GENERAL.............................................................................................................................147 CONTROL AND POWER FUSES - "LX" OR "ZX"..............................................................................................147 CONTROL AND POWER FUSES - SEM.......................................................................................................150 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"........................................................................153 THERMAL SENSORS - SEM...............................................................................................................153 ADJUST THE START SWITCH.............................................................................................................153 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3...............................................................154 Direction Switches (MONOTROL)...................................................................................................156 ADJUST THE BRAKE LIGHT SWITCH...................................................................................................156 CHECK SEAT SWITCH...............................................................................................................156 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE.......................................................................................156 ADJUST THE PARKING BRAKE SWITCH.................................................................................................157 DIRECTIONAL SWITCHES............................................................................................................157 DIRECTIONAL SWITCHES (STEERING COLUMN)..........................................................................................157 HYDRAULIC PUMP SWITCHES.........................................................................................................157 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT..................................................................................157 ADJUST THE ACCELERATOR POSITION SENSOR..........................................................................................158 Frame.......................................................................................................................................160 INTRODUCTION............................................................................................................................160 GENERAL.............................................................................................................................160 DESCRIPTION.........................................................................................................................160 Main Frame......................................................................................................................160 Other Frame Weldments...........................................................................................................162 Battery Restraint And Hood Frame................................................................................................163 Overhead Guard..................................................................................................................165 REPAIRS.................................................................................................................................165 OVERHEAD GUARD......................................................................................................................165 Removal.........................................................................................................................165 Installation....................................................................................................................165 BATTERY RESTRAINT AND SEAT ASSEMBLY.................................................................................................165 COUNTERWEIGHT.......................................................................................................................166 Removal.........................................................................................................................166 Installation....................................................................................................................167 TRACTION MOTOR......................................................................................................................168 Removing Traction Motor.........................................................................................................168 Installing Traction Motor.......................................................................................................169 HYRAULIC TANK.......................................................................................................................170 Inspection......................................................................................................................170 Repairs, Small Leaks............................................................................................................170 Repairs, Large Leaks............................................................................................................170 Cleaning........................................................................................................................171 Steam Method of Cleaning........................................................................................................171 Chemical Solution Method Of Cleaning............................................................................................171 Additional Preparations For Repair..............................................................................................171 PAINTING INSTRUCITONS...............................................................................................................172 LABEL REPLACEMENT...................................................................................................................174 Global Mast Description.....................................................................................................................175 INTRODUCTION............................................................................................................................175 GENERAL.............................................................................................................................175 DESCRIPTION AND OPERATION...........................................................................................................175 Carriages.......................................................................................................................175 Mast Mounts.....................................................................................................................176 TWO-STAGE MAST, LIMITED FREE-LIFT...................................................................................................177 Description and Operation.......................................................................................................177 TWO-STAGE MAST, FULL FREE-LIFT......................................................................................................179 Description.....................................................................................................................179 Operation.......................................................................................................................179 THREE-STAGE, FULL FREE-LIFT MAST....................................................................................................181 Description.....................................................................................................................181 Operation.......................................................................................................................181 Global Mast Repair..........................................................................................................................183 INTRODUCTION ...........................................................................................................................183 GENERAL ............................................................................................................................183 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ...........................................................................................183 REPAIRS ................................................................................................................................184 FORKS ..............................................................................................................................184 Removal ........................................................................................................................184 Installation ...................................................................................................................185 CARRIAGES ..........................................................................................................................185 Removal, Standard Carriage .....................................................................................................185 Removal, Side–Shift Carriage ...................................................................................................186 Repairs ........................................................................................................................186 Installation, Standard Carriage ................................................................................................186 Installation, Side–Shift Carriage ..............................................................................................187 MAST ...............................................................................................................................188 Removal ........................................................................................................................188 Disassembly, Three–Stage FFL Mast ..............................................................................................194 Disassembly, Two–Stage LFL And Two–Stage FFL Masts .............................................................................188 Cleaning and Inspection ........................................................................................................194 Assembly, Two–Stage LFL And Two–Stage FFL Mast .................................................................................197 Assembly, Three–Stage FFL Mast .................................................................................................198 Installation, Mast .............................................................................................................199 LIFT CYLINDERS .....................................................................................................................200 Removal, Main Lift Cylinders ...................................................................................................200 Removal, Free–Lift Cylinder ....................................................................................................200 Disassembly, Lift Cylinders ....................................................................................................200 Assembly, Lift Cylinders .......................................................................................................201 Installation, Main Lift Cylinders ..............................................................................................202 Installation, Free–Lift Cylinder ...............................................................................................203 HEADER HOSE ARRANGEMENTS H/S/E/J2.00–3.20XM (H/S/E/J40–65XM) S/E/J2.00–3.00XL (S/E/J40–60XL) .......................................204 New Hose Installation, Two–Stage, LFL Mast .....................................................................................204 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .....................................................................204 New Hose Installation, Two–Stage FFL Mast ......................................................................................208 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .....................................................................208 New Hose Installation, Three–Stage FFL Mast ....................................................................................212 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ..................................................................217 HEADER HOSE ARRANGEMENTS H/E1.50–1.75XM, H/S2.00XMS (H/S/E25–35XM, H/S/E40XMS) and J1.60–2.00XMT (J30–40XMT) .......................219 New Hose Installation, Two–Stage LFL Mast ......................................................................................220 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .....................................................................220 New Hose Installation, Two–Stage FFL Mast ......................................................................................223 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .....................................................................223 New Hose Installation, Three–Stage, FFL Mast ...................................................................................227 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ..................................................................232 CHECKS AND ADJUSTMENTS .................................................................................................................233 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM .......................................................................................233 Check The Lift Cylinders For Leaks ............................................................................................233 Check The Tilt Cylinders For Leaks ............................................................................................233 ADJUST THE TILT CYLINDERS .........................................................................................................233 ADJUST THE LIFT CHAINS ............................................................................................................234 ADJUST THE MAST ...................................................................................................................235 ADJUST THE CARRIAGE ...............................................................................................................236 TROUBLESHOOTING.........................................................................................................................237 Hydraulic System............................................................................................................................238 INTRODUCTION............................................................................................................................238 GENERAL.............................................................................................................................238 DESCRIPTION.........................................................................................................................239 Hydraulic System................................................................................................................239 OPERATION...........................................................................................................................239 Hydraulic System................................................................................................................239 Hydraulic Gear Pump.............................................................................................................240 Rotator Actuator Valve..........................................................................................................240 Steering Pump...................................................................................................................243 REPAIRS.................................................................................................................................247 HYDRAULIC TANK......................................................................................................................247 E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal.................................................................................247 J2.00-3.20XM (J40-65XM) Tank Removal............................................................................................247 Tank Inspection.................................................................................................................247 Tank Repairs, Small Leaks.......................................................................................................248 Tank Repairs, Large Leaks ......................................................................................................248 Tank Cleaning...................................................................................................................248 Steam Method Of Cleaning Tank...................................................................................................248 Chemical Solution Method Of Cleaning Tank.......................................................................................248 Additional Preparations For Tank repair.........................................................................................249 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation............................................................................249 J2.00-3.20XM (J40-65XM) Tank Installation.......................................................................................249 FILTER REPLACEMENT..................................................................................................................250 HYDRAULIC PUMP......................................................................................................................250 Removing E1.50-3.20XM (E25-65XM) and N30XMH Hydraulic Pump......................................................................250 Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump...............................................................................251 Pump Seal Replacement And Pump Assembly.........................................................................................251 Assemble Pump On The Motor......................................................................................................253 Install The Hydraulic Pump And Motor Assembly [E1.50-3.20XM (E25-65XM) and N30XMH]..............................................254 Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly...............................................................254 MAIN CONTROL VALVE..................................................................................................................255 STEERING PUMP.......................................................................................................................255 Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N30XMH................................................................255 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM)...........................................................................256 Pump Assembly And Installation..................................................................................................257 ROTARY ACTUATOR VALVE...............................................................................................................258 Disassembly, Cleaning and Inspection............................................................................................258 Assembly........................................................................................................................258 STEERING CONTROL UNIT...............................................................................................................258 Control Unit Removal............................................................................................................259 Control Unit Installation.......................................................................................................259 STEERING CYLINDER...................................................................................................................259 CHECKS AND ADJUSTMENTS..................................................................................................................261 MAIN CONTROL VALVE..................................................................................................................261 STEERING RELIEF VALVE...............................................................................................................261 TROUBLESHOOTING CHART...................................................................................................................261 SPECIFICATIONS..........................................................................................................................265 Industrial Battery..........................................................................................................................268 INTRODUCTION............................................................................................................................268 GENERAL.............................................................................................................................268 LEAD-ACID BATTERIES.................................................................................................................268 SPECIFIC GRAVITY....................................................................................................................269 CHEMICAL REACTION IN A CELL.........................................................................................................269 ELECTRICAL TERMS....................................................................................................................270 HOW TO SELECT THE BATTERY...........................................................................................................270 VOLTAGE OF A BATTERY................................................................................................................270 THE BATTERY AS A COUNTERWEIGHT......................................................................................................271 BATTERY RATINGS.....................................................................................................................271 Kilowatt-Hours..................................................................................................................272 BATTERY MAINTENANCE.....................................................................................................................272 SAFETY PROCEDURES...................................................................................................................272 MAINTENCE RECORDS...................................................................................................................273 THE NEW BATTERY.....................................................................................................................273 HOW TO CLEAN THE BATTERY............................................................................................................274 HOW TO ADD WATER....................................................................................................................274 THE HYDROMETER......................................................................................................................275 BATTERY TEMPERATURE.................................................................................................................275 CHARGING THE BATTERY................................................................................................................276 Types Of Battery Charges........................................................................................................277 Methods Of Charging.............................................................................................................278 Troubleshooting The Charger.....................................................................................................278 How to Know When The Battery Is Fully Charged...................................................................................279 WHERE TO CHARGE THE BATTERIES.......................................................................................................279 Equipment Needed................................................................................................................279 BATTERY CONNECTORS..................................................................................................................280 BATTERY CARE........................................................................................................................280 Instrument Cluster..........................................................................................................................282 INTRODUCTION............................................................................................................................282 GENERAL.............................................................................................................................282 DESCRIPTION.........................................................................................................................282 REPAIRS.................................................................................................................................286 REMOVAL AND DISASSEMBLY.............................................................................................................286 ASSEMBLY AND INSTALLATION...........................................................................................................286 Main Control Valve..........................................................................................................................289 INTRODUCTION............................................................................................................................289 GENERAL.............................................................................................................................289 DESCRIPTION.........................................................................................................................289 OPERATION...........................................................................................................................290 E1.50-3.20XM (E25-65XM).........................................................................................................291 J2.00-3.20XM (J40-65XM).........................................................................................................291 Lift Section....................................................................................................................291 Tilt Section....................................................................................................................292 Relief Valve....................................................................................................................294 REPAIRS.................................................................................................................................295 MAIN CONTROL VALVE..................................................................................................................295 Removal.........................................................................................................................295 Disassembly.....................................................................................................................295 Cleaning And Inspection.........................................................................................................295 Assembly........................................................................................................................295 Installation, E1.50-3.20XM (E25-65XM)...........................................................................................297 Installation, J2.00-3.20XM (J40-65XM)...........................................................................................299 CONTROL LEVER LINKAGE, E1.50-3.20XM (E25-65XM)......................................................................................300 Removal.........................................................................................................................300 Disassembly.....................................................................................................................301 Assembly And Installation.......................................................................................................301 CONTROL VALVE LINKAGE, E1.50-3.20XM (E25-65XM)......................................................................................301 Removal And Disassembly.........................................................................................................301 Assembly And Installation.......................................................................................................302 CONTROL LEVER LINKAGE, J2.00-3.20XM (J40-65XM)......................................................................................302 Removal.........................................................................................................................302 Disassembly.....................................................................................................................302 Assembly And Installation.......................................................................................................304 CHECKS AND ADJUSTMENTS..................................................................................................................305 PRESSURE RELIEF VALVES..............................................................................................................305 Primary Relief Valve............................................................................................................305 Secondary Relief Valve..........................................................................................................305 TROUBLESHOOTING.........................................................................................................................306 Periodic Maintenance.......................................................................................................................308 INTRODUCTION............................................................................................................................308 GENERAL.............................................................................................................................308 SERIAL NUMBER DATA..................................................................................................................308 HOW TO MOVE A DISABLED LIFT TRUCK...................................................................................................308 How To Tow A Lift Truck ........................................................................................................308 HOW TO PUT A LIFT TRUCK ON BLOCKS...................................................................................................309 How To Raise The Drive Tires....................................................................................................309 How To Raise The Steering Tires.................................................................................................309 MAINTENANCE SCHEDULE....................................................................................................................310 MAINTENANCE PROCEDURES..................................................................................................................313 EVERY 8 HOURS OR DAILY..................................................................................................................313 Tires And Wheels....................................................................................................................313 Forks...............................................................................................................................314 Fork Adjustment.....................................................................................................................314 Fork Removal........................................................................................................................314 Fork Installation...................................................................................................................315 Inspection Of Forks, Mast And Lift Chains...........................................................................................315 Safety Labels.......................................................................................................................316 Steering Column Latch...............................................................................................................316 Operator Restraint System...........................................................................................................317 Battery Restraint System, E25-65XM, E25-65XM2......................................................................................317 Battery Restraint System - J40-65XM-65XM, J40-65XM2................................................................................318 Battery.............................................................................................................................318 Hydraulic System....................................................................................................................319 HOW TO MAKE CHECKS WITH THE KEY "ON"................................................................................................320 Gauges, Horn And Fuses..........................................................................................................320 Steering System.................................................................................................................320 Service Brake...................................................................................................................320 Parking Brake...................................................................................................................321 Control Levers And Pedals.......................................................................................................321 Lift System Operation...........................................................................................................321 EVERY 350 HOURS OR THREE MONTHS ........................................................................................................322 HYDRAULIC TANK BREATHER.............................................................................................................322 DIFFERENTIAL AND SPEED REDUCER......................................................................................................322 WHEEL NUT TORQUES...................................................................................................................323 STEERING AXLE SPINDLES..............................................................................................................323 MAST................................................................................................................................323 LIFT CHAINS.........................................................................................................................324 Check For Wear..................................................................................................................324 Lubrication.....................................................................................................................324 FORKS...............................................................................................................................324 BRAKE FLUID.........................................................................................................................325 OTHER LUBRICATION...................................................................................................................325 SEAT BRAKE (E25-65XM, E25-65XM2 Only................................................................................................325 ELECTRICAL INSPECTION...............................................................................................................325 Contactors......................................................................................................................326 Motor Brushes...................................................................................................................326 Motor Brushes, General..........................................................................................................326 EVERY 2000 HOURS OR YEARLY..............................................................................................................336 HYDRAULIC SYSTEM....................................................................................................................336 Change The Filter For The Hydraulic Oil.........................................................................................336 Change The Hydraulic Oil........................................................................................................337 DIFFERENTIAL AND SPEED REDUCER......................................................................................................337 SERVICE BRAKES......................................................................................................................337 CONTACTORS..........................................................................................................................338 WHEEL BEARINGS......................................................................................................................338 Steer Wheels, Lubrication.......................................................................................................338 Drive Wheels, Lubrication.......................................................................................................338 LIFT CHAINS.........................................................................................................................338 GENERAL PROCEDURE.......................................................................................................................338 HOW TO CHARGE THE BATTERY...........................................................................................................338 HOW TO CHANGE THE BATTERY...........................................................................................................340 General.........................................................................................................................340 Change The E25-65XM, E25-65XM2 Battery..........................................................................................340 Change The J40-65XM, J40-65XM2 Battery..........................................................................................342 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.........................................................................................344 Check The Lift Cylinders For Leaks..............................................................................................344 Check The Tilt Cylinders For Leaks..............................................................................................344 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)...............................................................................345 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)...............................................................................346 LIFT CHAIN ADJUSTMENTS..............................................................................................................346 HOW TO CHECK THE PMT CIRCUIT........................................................................................................347 WELDING REPAIRS.....................................................................................................................348 CHANGES TO THE OVERHEAD GUARD.......................................................................................................348 TIRES AND WHEELS, E25-65XM, E25-65XM2...............................................................................................348 Remove The Wheels From The Lift Truck..........................................................................................349 Remove And Install The Tire On The Wheel........................................................................................349 PNEUMATIC TIRES AND WHEELS J40-65XM, J40-65XM2......................................................................................349 Remove The Wheels From The Lift Truck...........................................................................................349 Remove The Wheel From The Pneumatic Tire........................................................................................350 Install The Wheel In The Pneumatic Tire.........................................................................................351 Add Air To The Tires............................................................................................................352 Install The Wheels..............................................................................................................352 SOLID RUBBER TIRES ON PNEUMATIC WHEELS..............................................................................................352 Remove The Wheels From The Lift Truck...........................................................................................352 Remove The Solid Rubber Tire From The Pneumatic Wheel...........................................................................352 Install The Solid Rubber Tire On The Pneumatic Wheel............................................................................354 Install The Wheels .............................................................................................................354 REFERENCE TABLE.........................................................................................................................355 Adhesive And Sealants ..............................................................................................................355 SAE & Metric Fasteners......................................................................................................................356 INTRODUCTION............................................................................................................................356 NOMENCLATURE, THREADS...............................................................................................................356 STRENGTH IDENTIFICATION.............................................................................................................357 TABLE 1. BOLTS AND SCREWS...............................................................................................................357 TABLE 2. STUDS AND NUTS.................................................................................................................358 TABLE 3. TORQUE NUTS....................................................................................................................359 TABLE 4. TORQUE NUTS WITH NYLON INSERT..................................................................................................360 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...............................................................................................361 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.............................................................................................362 SEM Display Panel...........................................................................................................................365 SEM DISPLAY PANEL.......................................................................................................................365 GENERAL.............................................................................................................................365 SEM DISPLAY PANEL FEATURES..........................................................................................................365 Description Of Common Features..................................................................................................365 LED SYMBOL INDICATORS...........................................................................................................365 LED SCREEN .....................................................................................................................365 BATTERY DISCHARGE INDICATOR (BDI)...............................................................................................365 SERVCE REMINDER.................................................................................................................366 STATUS CODES....................................................................................................................366 HOURMETER.......................................................................................................................366 Additional Features Of Premium Display Panel....................................................................................366 Descriptions Of Additional Features (Available With The Premium Display)........................................................366 LCD SCREEN......................................................................................................................366 OPERATOR PASSWORDS..............................................................................................................366 DAILY CHECK LIST AND SERVICE ITEMS..............................................................................................367 PERFORMANCE MODES...............................................................................................................367 STATUS CODES LIST...............................................................................................................367 ADJUSTMENT OF BDI...............................................................................................................368 SEM DISPLAY PANEL INDICATORS........................................................................................................368 All Indicator Symbols...........................................................................................................368 Hourmeter Indicator Symbol......................................................................................................369 Wrench Indicator Symbol.........................................................................................................369 Battery Indicator Symbol........................................................................................................369 Battery State-Of-Charge (BDI)...................................................................................................369 Brake Fluid Too Low Symbol......................................................................................................369 Parking Brake Symbol............................................................................................................369 Fasten Seat Belt Symbol.........................................................................................................369 LCD Screen (Standard Display Panel).............................................................................................369 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL..................................................................................369 Alpha Numeric Screen............................................................................................................369 "STAR" Push Button..............................................................................................................370 Push Buttons #1 Through #5......................................................................................................370 ADJUSTMENTS WITH A COMPUTER.........................................................................................................371 COMPUTER SYSTEM.................................................................................................................371 Connect A PC To The SEM Display Panel...........................................................................................371 ITW SWITCHES SOFTWARE PROGRAM (For SEM Display Panel)...........................................................................372 Description.................................................................................................................372 Where To Get Help...........................................................................................................372 Hardware And Software Requirements..........................................................................................372 How To Start The ITW SWITCHES Program.......................................................................................373 Menus.......................................................................................................................373 Create A Setup File.........................................................................................................381 REPLACEMENT.........................................................................................................................401 GENERAL.........................................................................................................................401 SEM DISPLAY PANEL...............................................................................................................401 Removal And Replacement ........................................................................................................401 SR-SP Motor Controller Description & Operation..............................................................................................404 TRANSISTOR MOTOR CONTROLLERS (SR AND SP) DESCRIPTION, CHECKS & ADJUSTMENTS, TROUBLESHOOTING, REPAIRS, AND THEORY OF OPERATION...........404 DESCRIPTION.........................................................................................................................404 General.........................................................................................................................404 Model Number Data For Transistor Motor Controllers (SR and SP)..................................................................405 MOTOR CONTROLLER, CHECKS AND ADJUSTMENTS............................................................................................407 CHECKS AND ADJUSTMENTS USING A HAND SET.............................................................................................408 General.........................................................................................................................408 Connect Hand Set................................................................................................................409 Start Sequence..................................................................................................................409 Check Or Delete Stored Status Codes.............................................................................................409 Returning The Lift Truck To Normal Operation....................................................................................410 Checks And Adustments On The Work Bench.........................................................................................410 How To Check And Adjust The Registers...........................................................................................412 ADJUSTMENTS - FUNCTION PARAMETERS...................................................................................................413 General.........................................................................................................................413 Function Numbers................................................................................................................413 When The Hand Set Is Connected To A Motor Controller In The Lift Truck..........................................................414 FUNCTION NUMBER DESCRIPTIONS........................................................................................................415 TRACTION MOTOR CONTROLLER (LABEL LETTER - SR).......................................................................................415 FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY...........................................................................................420 PUMP MOTOR CONTROLLER (LABEL LETTER - SP)...........................................................................................422 FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY...........................................................................................425 TROUBLESHOOTING - STATUS CODE CHARTS....................................................................................................430 TROUBLESHOOTING.....................................................................................................................431 General.........................................................................................................................431 Status Codes....................................................................................................................431 REPAIRS.................................................................................................................................459 GENERAL.............................................................................................................................459 GENERAL MAINTENANCE INSTRUCTIONS....................................................................................................459 Special Precautions.............................................................................................................459 FUSES...............................................................................................................................462 CONTACTORS..........................................................................................................................462 Contactor Repair................................................................................................................462 CONTACTOR DRIVER MODULE.............................................................................................................464 Replace Contactor Driver........................................................................................................464 MOTOR CONTROLLER PLUG...............................................................................................................464 BRUSH WEAR INDICATORS...............................................................................................................464 THERMAL SENSORS.....................................................................................................................465 REPLACE MOTOR CONTROLLER............................................................................................................465 THEORY OF OPERATION.....................................................................................................................470 GENERAL.............................................................................................................................470 DESCRIPTION OF SEM SYSTEM...........................................................................................................470 OPERATION OF SEM SYSTEM (SR MOTOR CONTROLLER).......................................................................................471 Reverse Circuit.................................................................................................................471 Performance and Efficiency......................................................................................................471 Field Weakening.................................................................................................................472 Regenerative Braking............................................................................................................472 INTRODUCTION........................................................................................................................472 General.........................................................................................................................472 Creep Speed.....................................................................................................................472 Controlled Acceleration.........................................................................................................472 Current Limit...................................................................................................................473 BRAKING.............................................................................................................................473 Regenerative Braking to Zero Speed..............................................................................................473 Pedal Position Braking..........................................................................................................473 Auto Braking....................................................................................................................473 AUXILIARY SPEED CONTROL.............................................................................................................473 Field Weakening.................................................................................................................473 Speed Limits....................................................................................................................474 RAMP OPERATION......................................................................................................................474 Ramp Start......................................................................................................................474 Anti-Rollback...................................................................................................................474 STEER PUMP CONTACTOR TIME DELAY.....................................................................................................474 COIL DRIVERS AND INTERNAL COIL SUPPRESSION..........................................................................................474 SYSTEM PROTECTIVE OVERRIDE..........................................................................................................474 SRO (Static Return to Off)......................................................................................................474 Accelerator Volts Hold Off......................................................................................................474 Pulse Monitor Trip (PMT)........................................................................................................474 Thermal Protector (TP)..........................................................................................................475 Low Voltage.....................................................................................................................475 SP PUMP MOTOR CONTROLLERS...........................................................................................................475 CONTACTOR DRIVER MODULE.............................................................................................................475 DIAGNOSTICS.........................................................................................................................476 System Diagnostics..............................................................................................................476 Standard Status Codes...........................................................................................................476 Stored Status Codes.............................................................................................................476 Hourmeter Readings..............................................................................................................476 Maintenance Management Capability...............................................................................................476 SR-SP Motor Controller Parameter Tables.....................................................................................................482 SR (SEM) AND SP TRANSISTOR MOTOR CONTROLLER,Parameter Tables............................................................................482 GENERAL.............................................................................................................................482 Function Numbers...............................................................................................................482 MOTOR CONTROLLER CHECKS AND ADJUSTMENTS.............................................................................................483 TABLE 1.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V) (Standard Speed Motor With EE ....484 Parameter Tables................................................................................................................483 TABLE 2.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V) (High Speed Motor With E or ES....486 TABLE 3.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V).............................................488 TABLE 4.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E45-65XM2 (F108) (36 to 48V) (9 Inch Traction Motor)...........490 TABLE 5.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E45-65XM2 (F108) (36 to 48V) (11 Inch Traction Motor)..........493 TABLE 6.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER -E45-65XM2 (F108) (36 to 48V)..............................................496 TABLE 7.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER -J45-65XM2 (A216) (36 to 48V) (E OR ES RATED)....................498 TABLE 8.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER -J45-65XM2 (A216) (36 to 48V) (EE RATED).........................500 TABLE 9.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - J45-65XM2 (A216) (36 to 48V).............................................502 TABLE 10.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V) (9 INCH MOTOR).....................504 TABLE 11.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V) (11 INCH MOTOR)....................507 TABLE 12.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V)..............................................510 SR-SP Troubleshooting & Adjustments.........................................................................................................512 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers................................512 COMPUTER SYSTEM.....................................................................................................................512 Connect A PC To A Control Card..................................................................................................513 HYTECt SOFTWARE PROGRAM ............................................................................................................514 How To Start The Program........................................................................................................514 Selecting The Communications Port...............................................................................................515 Verification Of Controller and Lift Truck.......................................................................................515 Select The Lift Truck Series....................................................................................................516 Undefined Controller Card.......................................................................................................517 Controller Card Register Parameter List.........................................................................................517 How To Enter A New Parameter....................................................................................................518 How To Save A Changed Parameter File............................................................................................519 How To Load A Saved Parameter File..............................................................................................519 How To Return To Factory Default Settings.......................................................................................520 How To Save Changes To The Controller Card......................................................................................521 How To View The Status Codes ...................................................................................................521 Saving The Status Code To Disk..................................................................................................522 Closing and Clearing The Status Code List.......................................................................................523 COMMUNICATIONS PROGRAM (MODEM)......................................................................................................523 Requirements....................................................................................................................524 README File.....................................................................................................................525 GE Sentry Software..................................................................................................................525 Getting Started.................................................................................................................525 Where To Get Help...............................................................................................................526 Hardware and Software Requirements..............................................................................................526 Installation of the GE SENTRY SOFTWARE..........................................................................................526 How To Start The GE SENTRY Program..............................................................................................526 How To Reset The MIN and MAX Display............................................................................................528 How To Exit The GE SENTRY Program...............................................................................................528 Steering Axle...............................................................................................................................529 INTRODUCTION............................................................................................................................529 GENERAL.............................................................................................................................529 DESCRIPTION.........................................................................................................................529 REPAIRS.................................................................................................................................530 STEERING AXLE ASSEMBLY..............................................................................................................530 Removal.........................................................................................................................530 Installation....................................................................................................................531 WHEELS AND HUBS.....................................................................................................................531 Removal and Disassembly.........................................................................................................531 Cleaning........................................................................................................................533 Assembly And Installation.......................................................................................................533 SPINDLES, BEARINGS AND LINKS........................................................................................................533 Removal And Disassembly.........................................................................................................533 Cleaning and Inspection.........................................................................................................534 Assembly and Installation.......................................................................................................534 TORQUE SPECIFICATIONS...................................................................................................................535 TROUBLESHOOTING.........................................................................................................................536 Steering Housing & Control Unit.............................................................................................................537 INTRODUCTION............................................................................................................................537 GENERAL.............................................................................................................................537 DESCRIPTION.........................................................................................................................537 OPERATION...........................................................................................................................537 REPAIRS.................................................................................................................................538 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................................................538 Removal of the Assembly Components..............................................................................................542 Disassembly of the Steering Control Unit........................................................................................543 Cleaning of the Steering Control Unit...........................................................................................543 Assembly of the Steering Control Unit...........................................................................................543 Installation of the Steering Control Unit.......................................................................................543 Installation of the Assembly Components.........................................................................................543 CHECKS AND ADJUSTMENTS..................................................................................................................551 REMOVE AIR FROM THE SYSTEM..........................................................................................................551 TROUBLESHOOTING.........................................................................................................................551 Steering System.............................................................................................................................553 STEERING SYSTEM.........................................................................................................................553 GENERAL.............................................................................................................................553 DESCRIPTION.........................................................................................................................555 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................................................556 Removal Of The Assembly Components..............................................................................................556 Installation Of The Assembly Components.........................................................................................560 POWER STEERING MOTOR AND PUMP...........................................................................................................561 DESCRIPTION.........................................................................................................................561 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)..................................561 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3).......................................................................561 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)....................................................................................562 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)...................................................................................564 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)..................................................................................565 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]......................................565 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)..................................................................................566 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)................................................................................568 REPAIRS, POWER STEERING PUMP........................................................................................................569 Seal Replacement................................................................................................................570 HYDRAULIC STEERING MOTOR................................................................................................................570 DESCRIPTION.........................................................................................................................570 REPAIRS, HYDRAULIC STEERING MOTOR...................................................................................................571 Removal ........................................................................................................................571 Disassembly.....................................................................................................................571 Cleaning And Inspection.........................................................................................................571 Assembly........................................................................................................................572 Installation, Hydraulic Steering Motor..........................................................................................573 CHECKS AND ADJUSTMENTS..................................................................................................................573 AIR IN THE STEERING SYSTEM..........................................................................................................573 CHECK STEERING PRESSURE.............................................................................................................573 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only).......................................................................574 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS.......................................................................................575 TROUBLESHOOTING.........................................................................................................................577 Tilt Cylinder...............................................................................................................................580 INTRODUCTION............................................................................................................................580 GENERAL.............................................................................................................................580 DESCRIPTION.........................................................................................................................580 REPAIRS.................................................................................................................................580 REMOVAL.............................................................................................................................580 DISASSEMBLY.........................................................................................................................580 CLEANING............................................................................................................................580 ASSEMBLY............................................................................................................................580 Tilt Cylinders with O-Rings or Single Lip Seals.................................................................................580 Tilt Cylinders for the XM and XMS Models........................................................................................581 Tilt Cylinders for H700 800A and Early Model H700 920B..........................................................................583 INSTALLATION........................................................................................................................583 Tilt Cylinders Using Chevron Packing............................................................................................584 CHECKS AND ADJUSTMENTS..................................................................................................................586 CHECK THE TILT CYLINDERS FOR LEAKS..................................................................................................586 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.............................................................................586 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS................................................................................587 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS...............................................................................588 TROUBLESHOOTING.........................................................................................................................590
HYSTER D114 (E25-35XM₂, E40XMS₂) SERVICE MANUAL – PDF DOWNLOAD:
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