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Hyster D114 (E25-35XM, E40XMS) Service Manual – PDF DOWNLOAD
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Description
Hyster D114 (E25-35XM, E40XMS) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster D114 (E25-35XM, E40XMS) Service Manual – PDF DOWNLOAD
Language : English
Pages : 548
Downloadable : Yes
File Type : PDF
Size: 15.6 MB
TABLE OF CONTENTS:
Hyster D114 (E25-35XM, E40XMS) 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 Drive Axle SPD Reducer & Differential.......................................................................................... 85 INTRODUCTION............................................................................................................... 85 GENERAL................................................................................................................ 85 DESCRIPTION............................................................................................................ 85 REPAIRS.................................................................................................................... 85 DRIVE UNIT ASSEMBLY.................................................................................................... 85 Remove The Complete Drive Unit Assembly As A Unit.................................................................. 85 Traction Motor, Removal............................................................................................ 86 Drive Unit And Speed Reducer, Removal.............................................................................. 87 Disassembly Of The Drive Axle...................................................................................... 88 Disassembly Of The Differential And Speed Reducer.................................................................. 89 Cleaning........................................................................................................... 90 Inspection......................................................................................................... 90 ASSEMBLY OF THE DRIVE UNIT............................................................................................. 90 Find The Correct Shim Set For The Hypoid Gear...................................................................... 90 Assembly And Installation Of Pinion................................................................................ 91 Assembly Of The Differential And Ring Gear......................................................................... 92 Input Gear For The Speed Reducer, Assembly......................................................................... 96 Drive Axle And Hub Assembly, Assembly.............................................................................. 96 INSTALLATION OF DRIVE UNIT............................................................................................. 97 Drive Unit, Installation........................................................................................... 97 Traction Motor, Installation....................................................................................... 98 TORQUE SPECIFICATIONS...................................................................................................... 99 TROUBLESHOOTING............................................................................................................ 99 Electrical System..............................................................................................................100 ELECTRICAL SYSTEM..........................................................................................................100 GENERAL................................................................................................................100 "LX" SERIES DISPLAY PANEL..............................................................................................101 Hourmeter Functions................................................................................................102 Battery Indicator Function.........................................................................................102 Status Code Function...............................................................................................103 "ZX" SERIES DISPLAY PANELS.............................................................................................103 Display Panel......................................................................................................103 Basic Display Panels...............................................................................................103 Performance Display................................................................................................105 Brush Wear Indicators..............................................................................................108 SEM DISPLAY PANELS - FEATURES..........................................................................................108 Description Of Common Features.....................................................................................109 LED SYMBOL INDICATORS..............................................................................................109 LCD SCREEN.........................................................................................................109 BATTERY DISCHARGE INDICATOR (BDI)..................................................................................109 SERVICE REMINDER...................................................................................................109 STATUS CODES.......................................................................................................109 HOURMETER..........................................................................................................109 Additional Features Of Premium Display Panel ......................................................................109 Descriptions Of Additional Features (Available With The Premium Display) ..........................................110 LCD SCREEN.........................................................................................................110 OPERATOR PASSWORDS.................................................................................................110 DAILY CHECK LIST AND SERVICE ITEMS.................................................................................110 PERFORMANCE MODELS.................................................................................................110 STATUS CODE LISTS..................................................................................................110 ADJUSTMENTS OF BDI.................................................................................................111 SEM DISPLAY PANEL INDICATORS...........................................................................................111 All Indicator Symbols..............................................................................................111 Hourmeter Indicator Symbol.........................................................................................112 Wrench Indicator Symbol............................................................................................112 Battery Indicator Symbol...........................................................................................112 Battery State-Of-Charge (BDI)......................................................................................112 Brake Fluid Too Low Symbol.........................................................................................112 Parking Brake Symbol...............................................................................................112 Fasten Seat Belt Symbol............................................................................................112 LCD "Screen" (Standard Display Panel)..............................................................................112 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM................................................................112 Alpha Numeric "Screen".............................................................................................112 "Star" Push Button.................................................................................................113 Push Buttons #1 Through #5.........................................................................................113 OTHER CONTROL COMPONENTS...............................................................................................113 REPLACEMENT................................................................................................................114 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"...............................................................................114 Replace The Display Panel Assembly.................................................................................114 Replace The Key Switch.............................................................................................115 Indicator LEDs.....................................................................................................115 Battery Indicators.................................................................................................115 Digital Display (Performance Display Panel Only) ..................................................................115 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only).......................117 Replace Parts Of The Basic Display Panel ..........................................................................117 Replace Parts Of The Performance Display Panel.....................................................................118 SEM DISPLAY PANEL......................................................................................................119 Removal And Replacement............................................................................................119 REPLACE MOTOR CONTROLLER (SR or SP)....................................................................................119 OTHER CONTROL COMPONENTS...............................................................................................119 Start Swtich.......................................................................................................119 Brake Light Switch.................................................................................................120 Seat Switch........................................................................................................121 Adjust The External Seat Switch....................................................................................122 Switch For Optional Seat Brake.....................................................................................122 Parking Brake Switch...............................................................................................122 Direction Switches (Monotrol Pedal)...............................................................................123 Direction Control Switches (Steering Column).......................................................................124 Direction Control Switches, E70-120XL3 (Steering Column)...........................................................125 Brake Fluid Switch.................................................................................................125 Brush Wear And Over Temperature Sensors............................................................................125 Rocker Switches For Lights ........................................................................................126 Accelerator Position Sensor........................................................................................126 On-Demand Steering Components......................................................................................128 Lights, Converter, Relay And Reverse Alarm.........................................................................130 Horn And Horn Buttons..............................................................................................133 Hydraulic Pump Switches............................................................................................134 CHECKS AND ADJUSTMENTS.....................................................................................................134 GENERAL................................................................................................................134 CONTROL AND POWER FUSES - "LX" OR "ZX".................................................................................134 CONTROL AND POWER FUSES - SEM..........................................................................................137 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"...........................................................140 THERMAL SENSORS - SEM..................................................................................................140 ADJUST THE START SWITCH................................................................................................140 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3..................................................141 Direction Switches (MONOTROL)......................................................................................143 ADJUST THE BRAKE LIGHT SWITCH......................................................................................143 CHECK SEAT SWITCH..................................................................................................143 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE..........................................................................143 ADJUST THE PARKING BRAKE SWITCH....................................................................................144 DIRECTIONAL SWITCHES...............................................................................................144 DIRECTIONAL SWITCHES (STEERING COLUMN).............................................................................144 HYDRAULIC PUMP SWITCHES............................................................................................144 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT.....................................................................144 ADJUST THE ACCELERATOR POSITION SENSOR.............................................................................145 EV-100ZX Motor Controller DESCR & Repair.......................................................................................147 EV-100ZXE SCR MOTOR CONTROLLER, Description, Adjustments, Troubleshooting, Repairs, and Theory.............................147 GENERAL................................................................................................................147 Model Number Data For EV-100ZX Controller..........................................................................148 REGISTER PARAMETERS....................................................................................................157 General............................................................................................................157 Function Members...................................................................................................157 CONTROL CARD, CHECKS AND ADJUSTMENTS...................................................................................157 HAND SET...............................................................................................................158 How To Check And Adjust The Registers..............................................................................158 How To Scroll Through The Fault Codes And Clear Them...............................................................158 Checks And Adjustments On The Work Bench...........................................................................159 When The Hand Set Is Connected To A Control Card Installed In A Lift Truck.........................................160 FUNCTION NUMBER DESCRIPTIONS...........................................................................................161 TRACTION CONTROL CARDS (LABEL LETTERS - ZH AND ZY).....................................................................162 PUMP CONTROL CARD (LABEL LETTER ZP)....................................................................................168 REGISTER PARAMETERS....................................................................................................172 TROUBLESHOOTING........................................................................................................172 Status Codes.......................................................................................................173 REGISTER MAPS..........................................................................................................173 STATUS CODE CHARTS.........................................................................................................182 REPAIRS....................................................................................................................214 FUSES..................................................................................................................215 CHECK AN SCR...........................................................................................................215 THE SCR ASSEMBLY.......................................................................................................216 THERMAL PROTECTOR......................................................................................................216 REPLACE THE SCR 1 ASSEMBLY.............................................................................................216 THE "OFF" CIRCUIT FOR SCR 1............................................................................................216 Check The Reactor Assembly.........................................................................................216 Check Suppressors For SCR 2 And SCR 5..............................................................................217 Check SCR 2 And SCR 5..............................................................................................217 Replace SCR 2 And SCR 5............................................................................................217 Check Capacitor C1.................................................................................................217 DIODES D3 AND D4.......................................................................................................217 Check The Diodes D3 And D4.........................................................................................218 Replacement, Diodes D3 And D4......................................................................................218 MOTOR CURRENT SENSOR...................................................................................................218 CONTACTORS.............................................................................................................218 Contactor Repair...................................................................................................219 CONTROL CARD...........................................................................................................220 CONTROL CARD PLUGS.....................................................................................................221 Brush Wear Indicators..............................................................................................222 THEORY OF OPERATION........................................................................................................223 ELECTRONIC SPEED CONTROLS..............................................................................................223 The Silicon Controlled Rectifier (SCR).............................................................................223 A Motor Circuit That Operates With Pulses..........................................................................223 Traction Circuit...................................................................................................225 Hydraulic Pump Motor...............................................................................................225 The SCR 1 "OFF" Circuit............................................................................................226 INDUCTION CURRENT FROM THE MOTOR.......................................................................................228 CONTROL CARDS..........................................................................................................228 Pulse Monitor Trip (PMT) (Traction Circuit Only)...................................................................228 SRO Circuit (Traction Circuit Only)................................................................................229 SEQUENCE OF OPERATION..................................................................................................230 Control Card Adjustments (Traction Circuit)........................................................................230 Accelerator Control................................................................................................233 SCR CONTROL (HYDRAULIC PUMP MOTOR).....................................................................................233 CONTACTORS.............................................................................................................234 CIRCUIT PROTECTION.....................................................................................................235 Traction Circuit Fuse..............................................................................................235 Current Limit......................................................................................................235 Thermal Protection.................................................................................................235 Suppressors........................................................................................................235 TRUCK MANAGEMENT MODULE (TMM1).........................................................................................235 TABLE 8. Terminal And Plug Wire Connections For TMM1 Module........................................................236 DISPLAY PANELS.........................................................................................................236 Display Panel......................................................................................................236 Basic Display......................................................................................................236 Performance Display................................................................................................238 Brush Wear Indicators..............................................................................................241 EV-100ZX Motor Controller Parameter Tables.....................................................................................242 EV-100ZX SCR MOTOR CONTROLLER, Parameter Tables............................................................................242 REGISTER PARAMETERS....................................................................................................242 General............................................................................................................242 Function Number....................................................................................................243 CONTROL CARD, CHECKS AND ADJUSTMENTS...................................................................................243 TABLE 1. EV-100ZX Parameters (Heavey Duty Motor (8702303) [Traction Card Type ZH or Zy With Regenerative Braking...........244 TABLE 2. EV-100ZX Parameters (Heavy Duty Motor (8702303) [Traction Card Type ZH or ZY No Regenerative Braking..............247 TABLE 3. EV-100ZX Parameters (Standard Motor (P/N 8702301 or 8702302) [Traction Card Type ZH or ZY With Regen. Braking ....250 TABLE 4. EV-100ZX Parameters (Standard Motor (P/N 8702301 or 8702302) [Traction Card Type ZH or ZY No Regen. Braking......253 TABLE 5. EV-100ZX Parameters-(Standard Motor (P/N 8702301 or 8702302) (Low Energy System)(Traction Card Type ZH and ZY.....256 TABLE 6. EV-100ZX Parameters (Standard System) (Hydraulic Pump Card Type ZP With or Without Lift Interrupt)................259 TABLE 7. EV-100ZX Parameters (Low Energy System) (Hydraulic Pump Card Type ZP With or Without Lift Interrupt).............259 EV-100ZX-T100 Troubleshooting & Adjustment.....................................................................................265 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers...................265 COMPUTER SYSTEM........................................................................................................265 Connect A PC To A Control Card.....................................................................................266 HYTECt SOFTWARE PROGRAM ...............................................................................................267 How To Start The Program...........................................................................................267 Selecting The Communications Port..................................................................................268 Verification Of Controller and Lift Truck..........................................................................268 Select The Lift Truck Series.......................................................................................269 Undefined Controller Card..........................................................................................270 Controller Card Register Parameter List............................................................................270 How To Enter A New Parameter.......................................................................................271 How To Save A Changed Parameter File...............................................................................272 How To Load A Saved Parameter File.................................................................................272 How To Return To Factory Default Settings..........................................................................273 How To Save Changes To The Controller Card.........................................................................274 How To View The Status Codes ......................................................................................274 Saving The Status Code To Disk.....................................................................................275 Closing and Clearing The Status Code List..........................................................................276 COMMUNICATIONS PROGRAM (MODEM).........................................................................................276 Requirements.......................................................................................................277 README File........................................................................................................278 GE Sentry Software.....................................................................................................278 Getting Started....................................................................................................278 Where To Get Help..................................................................................................279 Hardware and Software Requirements.................................................................................279 Installation of the GE SENTRY SOFTWARE.............................................................................279 How To Start The GE SENTRY Program.................................................................................279 How To Reset The MIN and MAX Display...............................................................................281 How To Exit The GE SENTRY Program..................................................................................281 Frame..........................................................................................................................282 INTRODUCTION...............................................................................................................282 GENERAL................................................................................................................282 DESCRIPTION............................................................................................................282 Main Frame.........................................................................................................282 Other Frame Weldments..............................................................................................284 Battery Restraint And Hood Frame...................................................................................285 Overhead Guard.....................................................................................................287 REPAIRS....................................................................................................................287 OVERHEAD GUARD.........................................................................................................287 Removal............................................................................................................287 Installation.......................................................................................................287 BATTERY RESTRAINT AND SEAT ASSEMBLY....................................................................................287 COUNTERWEIGHT..........................................................................................................288 Removal............................................................................................................288 Installation.......................................................................................................289 TRACTION MOTOR.........................................................................................................290 Removing Traction Motor............................................................................................290 Installing Traction Motor..........................................................................................291 HYRAULIC TANK..........................................................................................................292 Inspection.........................................................................................................292 Repairs, Small Leaks...............................................................................................292 Repairs, Large Leaks...............................................................................................292 Cleaning...........................................................................................................293 Steam Method of Cleaning...........................................................................................293 Chemical Solution Method Of Cleaning...............................................................................293 Additional Preparations For Repair.................................................................................293 PAINTING INSTRUCITONS..................................................................................................294 LABEL REPLACEMENT......................................................................................................296 Global Mast Description........................................................................................................297 INTRODUCTION...............................................................................................................297 GENERAL................................................................................................................297 DESCRIPTION AND OPERATION..............................................................................................297 Carriages..........................................................................................................297 Mast Mounts........................................................................................................298 TWO-STAGE MAST, LIMITED FREE-LIFT......................................................................................299 Description and Operation..........................................................................................299 TWO-STAGE MAST, FULL FREE-LIFT.........................................................................................301 Description........................................................................................................301 Operation..........................................................................................................301 THREE-STAGE, FULL FREE-LIFT MAST.......................................................................................303 Description........................................................................................................303 Operation..........................................................................................................303 Global Mast Repair.............................................................................................................305 INTRODUCTION ..............................................................................................................305 GENERAL ...............................................................................................................305 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ..............................................................................305 REPAIRS ...................................................................................................................306 FORKS .................................................................................................................306 Removal ...........................................................................................................306 Installation ......................................................................................................307 CARRIAGES .............................................................................................................307 Removal, Standard Carriage ........................................................................................307 Removal, Side–Shift Carriage ......................................................................................308 Repairs ...........................................................................................................308 Installation, Standard Carriage ...................................................................................308 Installation, Side–Shift Carriage .................................................................................309 MAST ..................................................................................................................310 Removal ...........................................................................................................310 Disassembly, Three–Stage FFL Mast .................................................................................316 Disassembly, Two–Stage LFL And Two–Stage FFL Masts ................................................................310 Cleaning and Inspection ...........................................................................................316 Assembly, Two–Stage LFL And Two–Stage FFL Mast ....................................................................319 Assembly, Three–Stage FFL Mast ....................................................................................320 Installation, Mast ................................................................................................321 LIFT CYLINDERS ........................................................................................................322 Removal, Main Lift Cylinders ......................................................................................322 Removal, Free–Lift Cylinder .......................................................................................322 Disassembly, Lift Cylinders .......................................................................................322 Assembly, Lift Cylinders ..........................................................................................323 Installation, Main Lift Cylinders .................................................................................324 Installation, Free–Lift Cylinder ..................................................................................325 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) ..........................326 New Hose Installation, Two–Stage, LFL Mast ........................................................................326 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ........................................................326 New Hose Installation, Two–Stage FFL Mast .........................................................................330 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ........................................................330 New Hose Installation, Three–Stage FFL Mast .......................................................................334 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast .....................................................339 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) ..........341 New Hose Installation, Two–Stage LFL Mast .........................................................................342 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ........................................................342 New Hose Installation, Two–Stage FFL Mast .........................................................................345 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ........................................................345 New Hose Installation, Three–Stage, FFL Mast ......................................................................349 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast .....................................................354 CHECKS AND ADJUSTMENTS ....................................................................................................355 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ..........................................................................355 Check The Lift Cylinders For Leaks ...............................................................................355 Check The Tilt Cylinders For Leaks ...............................................................................355 ADJUST THE TILT CYLINDERS ............................................................................................355 ADJUST THE LIFT CHAINS ...............................................................................................356 ADJUST THE MAST ......................................................................................................357 ADJUST THE CARRIAGE ..................................................................................................358 TROUBLESHOOTING............................................................................................................359 Hydraulic System...............................................................................................................360 INTRODUCTION...............................................................................................................360 GENERAL................................................................................................................360 DESCRIPTION............................................................................................................361 Hydraulic System...................................................................................................361 OPERATION..............................................................................................................361 Hydraulic System...................................................................................................361 Hydraulic Gear Pump................................................................................................362 Rotator Actuator Valve.............................................................................................362 Steering Pump......................................................................................................365 REPAIRS....................................................................................................................369 HYDRAULIC TANK.........................................................................................................369 E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal....................................................................369 J2.00-3.20XM (J40-65XM) Tank Removal...............................................................................369 Tank Inspection....................................................................................................369 Tank Repairs, Small Leaks..........................................................................................370 Tank Repairs, Large Leaks .........................................................................................370 Tank Cleaning......................................................................................................370 Steam Method Of Cleaning Tank......................................................................................370 Chemical Solution Method Of Cleaning Tank..........................................................................370 Additional Preparations For Tank repair............................................................................371 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation...............................................................371 J2.00-3.20XM (J40-65XM) Tank Installation..........................................................................371 FILTER REPLACEMENT.....................................................................................................372 HYDRAULIC PUMP.........................................................................................................372 Removing E1.50-3.20XM (E25-65XM) and N30XMH Hydraulic Pump.........................................................372 Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump..................................................................373 Pump Seal Replacement And Pump Assembly............................................................................373 Assemble Pump On The Motor.........................................................................................375 Install The Hydraulic Pump And Motor Assembly [E1.50-3.20XM (E25-65XM) and N30XMH].................................376 Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly..................................................376 MAIN CONTROL VALVE.....................................................................................................377 STEERING PUMP..........................................................................................................377 Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N30XMH...................................................377 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM)..............................................................378 Pump Assembly And Installation.....................................................................................379 ROTARY ACTUATOR VALVE..................................................................................................380 Disassembly, Cleaning and Inspection...............................................................................380 Assembly...........................................................................................................380 STEERING CONTROL UNIT..................................................................................................380 Control Unit Removal...............................................................................................381 Control Unit Installation..........................................................................................381 STEERING CYLINDER......................................................................................................381 CHECKS AND ADJUSTMENTS.....................................................................................................383 MAIN CONTROL VALVE.....................................................................................................383 STEERING RELIEF VALVE..................................................................................................383 TROUBLESHOOTING CHART......................................................................................................383 SPECIFICATIONS.............................................................................................................387 Industrial Battery.............................................................................................................390 INTRODUCTION...............................................................................................................390 GENERAL................................................................................................................390 LEAD-ACID BATTERIES....................................................................................................390 SPECIFIC GRAVITY.......................................................................................................391 CHEMICAL REACTION IN A CELL............................................................................................391 ELECTRICAL TERMS.......................................................................................................392 HOW TO SELECT THE BATTERY..............................................................................................392 VOLTAGE OF A BATTERY...................................................................................................392 THE BATTERY AS A COUNTERWEIGHT.........................................................................................393 BATTERY RATINGS........................................................................................................393 Kilowatt-Hours.....................................................................................................394 BATTERY MAINTENANCE........................................................................................................394 SAFETY PROCEDURES......................................................................................................394 MAINTENCE RECORDS......................................................................................................395 THE NEW BATTERY........................................................................................................395 HOW TO CLEAN THE BATTERY...............................................................................................396 HOW TO ADD WATER.......................................................................................................396 THE HYDROMETER.........................................................................................................397 BATTERY TEMPERATURE....................................................................................................397 CHARGING THE BATTERY...................................................................................................398 Types Of Battery Charges...........................................................................................399 Methods Of Charging................................................................................................400 Troubleshooting The Charger........................................................................................400 How to Know When The Battery Is Fully Charged......................................................................401 WHERE TO CHARGE THE BATTERIES..........................................................................................401 Equipment Needed...................................................................................................401 BATTERY CONNECTORS.....................................................................................................402 BATTERY CARE...........................................................................................................402 Instrument Cluster.............................................................................................................404 INTRODUCTION...............................................................................................................404 GENERAL................................................................................................................404 DESCRIPTION............................................................................................................404 REPAIRS....................................................................................................................408 REMOVAL AND DISASSEMBLY................................................................................................408 ASSEMBLY AND INSTALLATION..............................................................................................408 Main Control Valve.............................................................................................................411 INTRODUCTION...............................................................................................................411 GENERAL................................................................................................................411 DESCRIPTION............................................................................................................411 OPERATION..............................................................................................................412 E1.50-3.20XM (E25-65XM)............................................................................................413 J2.00-3.20XM (J40-65XM)............................................................................................413 Lift Section.......................................................................................................413 Tilt Section.......................................................................................................414 Relief Valve.......................................................................................................416 REPAIRS....................................................................................................................417 MAIN CONTROL VALVE.....................................................................................................417 Removal............................................................................................................417 Disassembly........................................................................................................417 Cleaning And Inspection............................................................................................417 Assembly...........................................................................................................417 Installation, E1.50-3.20XM (E25-65XM)..............................................................................419 Installation, J2.00-3.20XM (J40-65XM)..............................................................................421 CONTROL LEVER LINKAGE, E1.50-3.20XM (E25-65XM).........................................................................422 Removal............................................................................................................422 Disassembly........................................................................................................423 Assembly And Installation..........................................................................................423 CONTROL VALVE LINKAGE, E1.50-3.20XM (E25-65XM).........................................................................423 Removal And Disassembly............................................................................................423 Assembly And Installation..........................................................................................424 CONTROL LEVER LINKAGE, J2.00-3.20XM (J40-65XM).........................................................................424 Removal............................................................................................................424 Disassembly........................................................................................................424 Assembly And Installation..........................................................................................426 CHECKS AND ADJUSTMENTS.....................................................................................................427 PRESSURE RELIEF VALVES.................................................................................................427 Primary Relief Valve...............................................................................................427 Secondary Relief Valve.............................................................................................427 TROUBLESHOOTING............................................................................................................428 Periodic Maintenance...........................................................................................................430 INTRODUCTION...............................................................................................................430 GENERAL................................................................................................................430 SERIAL NUMBER DATA.....................................................................................................430 HOW TO MOVE A DISABLED LIFT TRUCK......................................................................................430 How To Tow A Lift Truck ...........................................................................................430 HOW TO PUT A LIFT TRUCK ON BLOCKS......................................................................................431 How To Raise The Drive Tires.......................................................................................431 How To Raise The Steering Tires....................................................................................431 MAINTENANCE SCHEDULE.......................................................................................................432 MAINTENANCE PROCEDURES.....................................................................................................435 EVERY 8 HOURS OR DAILY.....................................................................................................435 Tires And Wheels.......................................................................................................435 Forks..................................................................................................................436 Fork Adjustment........................................................................................................436 Fork Removal...........................................................................................................436 Fork Installation......................................................................................................437 Inspection Of Forks, Mast And Lift Chains..............................................................................437 Safety Labels..........................................................................................................438 Steering Column Latch..................................................................................................438 Operator Restraint System..............................................................................................439 Battery Restraint System, E25-65XM, E25-65XM2.........................................................................439 Battery Restraint System - J40-65XM-65XM, J40-65XM2...................................................................440 Battery................................................................................................................440 Hydraulic System.......................................................................................................441 HOW TO MAKE CHECKS WITH THE KEY "ON"...................................................................................442 Gauges, Horn And Fuses.............................................................................................442 Steering System....................................................................................................442 Service Brake......................................................................................................442 Parking Brake......................................................................................................443 Control Levers And Pedals..........................................................................................443 Lift System Operation..............................................................................................443 EVERY 350 HOURS OR THREE MONTHS ...........................................................................................444 HYDRAULIC TANK BREATHER................................................................................................444 DIFFERENTIAL AND SPEED REDUCER.........................................................................................444 WHEEL NUT TORQUES......................................................................................................445 STEERING AXLE SPINDLES.................................................................................................445 MAST...................................................................................................................445 LIFT CHAINS............................................................................................................446 Check For Wear.....................................................................................................446 Lubrication........................................................................................................446 FORKS..................................................................................................................446 BRAKE FLUID............................................................................................................447 OTHER LUBRICATION......................................................................................................447 SEAT BRAKE (E25-65XM, E25-65XM2 Only...................................................................................447 ELECTRICAL INSPECTION..................................................................................................447 Contactors.........................................................................................................448 Motor Brushes......................................................................................................448 Motor Brushes, General.............................................................................................448 EVERY 2000 HOURS OR YEARLY.................................................................................................458 HYDRAULIC SYSTEM.......................................................................................................458 Change The Filter For The Hydraulic Oil............................................................................458 Change The Hydraulic Oil...........................................................................................459 DIFFERENTIAL AND SPEED REDUCER.........................................................................................459 SERVICE BRAKES.........................................................................................................459 CONTACTORS.............................................................................................................460 WHEEL BEARINGS.........................................................................................................460 Steer Wheels, Lubrication..........................................................................................460 Drive Wheels, Lubrication..........................................................................................460 LIFT CHAINS............................................................................................................460 GENERAL PROCEDURE..........................................................................................................460 HOW TO CHARGE THE BATTERY..............................................................................................460 HOW TO CHANGE THE BATTERY..............................................................................................462 General............................................................................................................462 Change The E25-65XM, E25-65XM2 Battery.............................................................................462 Change The J40-65XM, J40-65XM2 Battery.............................................................................464 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM............................................................................466 Check The Lift Cylinders For Leaks.................................................................................466 Check The Tilt Cylinders For Leaks.................................................................................466 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)..................................................................467 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)..................................................................468 LIFT CHAIN ADJUSTMENTS.................................................................................................468 HOW TO CHECK THE PMT CIRCUIT...........................................................................................469 WELDING REPAIRS........................................................................................................470 CHANGES TO THE OVERHEAD GUARD..........................................................................................470 TIRES AND WHEELS, E25-65XM, E25-65XM2..................................................................................470 Remove The Wheels From The Lift Truck.............................................................................471 Remove And Install The Tire On The Wheel...........................................................................471 PNEUMATIC TIRES AND WHEELS J40-65XM, J40-65XM2.........................................................................471 Remove The Wheels From The Lift Truck..............................................................................471 Remove The Wheel From The Pneumatic Tire...........................................................................472 Install The Wheel In The Pneumatic Tire............................................................................473 Add Air To The Tires...............................................................................................474 Install The Wheels.................................................................................................474 SOLID RUBBER TIRES ON PNEUMATIC WHEELS.................................................................................474 Remove The Wheels From The Lift Truck..............................................................................474 Remove The Solid Rubber Tire From The Pneumatic Wheel..............................................................474 Install The Solid Rubber Tire On The Pneumatic Wheel...............................................................476 Install The Wheels ................................................................................................476 REFERENCE TABLE............................................................................................................477 Adhesive And Sealants .................................................................................................477 SAE & Metric Fasteners.........................................................................................................478 INTRODUCTION...............................................................................................................478 NOMENCLATURE, THREADS..................................................................................................478 STRENGTH IDENTIFICATION................................................................................................479 TABLE 1. BOLTS AND SCREWS..................................................................................................479 TABLE 2. STUDS AND NUTS....................................................................................................480 TABLE 3. TORQUE NUTS.......................................................................................................481 TABLE 4. TORQUE NUTS WITH NYLON INSERT.....................................................................................482 TABLE 5. TORQUE VALUES FOR INCH FASTENERS..................................................................................483 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS................................................................................484 Steering Axle..................................................................................................................487 INTRODUCTION...............................................................................................................487 GENERAL................................................................................................................487 DESCRIPTION............................................................................................................487 REPAIRS....................................................................................................................488 STEERING AXLE ASSEMBLY.................................................................................................488 Removal............................................................................................................488 Installation.......................................................................................................489 WHEELS AND HUBS........................................................................................................489 Removal and Disassembly............................................................................................489 Cleaning...........................................................................................................491 Assembly And Installation..........................................................................................491 SPINDLES, BEARINGS AND LINKS...........................................................................................491 Removal And Disassembly............................................................................................491 Cleaning and Inspection............................................................................................492 Assembly and Installation..........................................................................................492 TORQUE SPECIFICATIONS......................................................................................................493 TROUBLESHOOTING............................................................................................................494 Steering Housing & Control Unit................................................................................................495 INTRODUCTION...............................................................................................................495 GENERAL................................................................................................................495 DESCRIPTION............................................................................................................495 OPERATION..............................................................................................................495 REPAIRS....................................................................................................................496 STEERING WHEEL AND COLUMN ASSEMBLY.....................................................................................496 Removal of the Assembly Components.................................................................................500 Disassembly of the Steering Control Unit...........................................................................501 Cleaning of the Steering Control Unit..............................................................................501 Assembly of the Steering Control Unit..............................................................................501 Installation of the Steering Control Unit..........................................................................501 Installation of the Assembly Components............................................................................501 CHECKS AND ADJUSTMENTS.....................................................................................................509 REMOVE AIR FROM THE SYSTEM.............................................................................................509 TROUBLESHOOTING............................................................................................................509 Steering System................................................................................................................511 STEERING SYSTEM............................................................................................................511 GENERAL................................................................................................................511 DESCRIPTION............................................................................................................513 STEERING WHEEL AND COLUMN ASSEMBLY.....................................................................................514 Removal Of The Assembly Components.................................................................................514 Installation Of The Assembly Components............................................................................518 POWER STEERING MOTOR AND PUMP..............................................................................................519 DESCRIPTION............................................................................................................519 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM).....................519 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)..........................................................519 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM).......................................................................520 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)......................................................................522 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS).....................................................................523 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)].........................523 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM).....................................................................524 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)...................................................................526 REPAIRS, POWER STEERING PUMP...........................................................................................527 Seal Replacement...................................................................................................528 HYDRAULIC STEERING MOTOR...................................................................................................528 DESCRIPTION............................................................................................................528 REPAIRS, HYDRAULIC STEERING MOTOR......................................................................................529 Removal ...........................................................................................................529 Disassembly........................................................................................................529 Cleaning And Inspection............................................................................................529 Assembly...........................................................................................................530 Installation, Hydraulic Steering Motor.............................................................................531 CHECKS AND ADJUSTMENTS.....................................................................................................531 AIR IN THE STEERING SYSTEM.............................................................................................531 CHECK STEERING PRESSURE................................................................................................531 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)..........................................................532 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS..........................................................................533 TROUBLESHOOTING............................................................................................................535 Tilt Cylinder..................................................................................................................538 INTRODUCTION...............................................................................................................538 GENERAL................................................................................................................538 DESCRIPTION............................................................................................................538 REPAIRS....................................................................................................................538 REMOVAL................................................................................................................538 DISASSEMBLY............................................................................................................538 CLEANING...............................................................................................................538 ASSEMBLY...............................................................................................................538 Tilt Cylinders with O-Rings or Single Lip Seals....................................................................538 Tilt Cylinders for the XM and XMS Models...........................................................................539 Tilt Cylinders for H700 800A and Early Model H700 920B.............................................................541 INSTALLATION...........................................................................................................541 Tilt Cylinders Using Chevron Packing...............................................................................542 CHECKS AND ADJUSTMENTS.....................................................................................................544 CHECK THE TILT CYLINDERS FOR LEAKS.....................................................................................544 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE................................................................544 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS...................................................................545 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS..................................................................546 TROUBLESHOOTING............................................................................................................548
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