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Hyster E160 (J1.60XMT, J1.80XMT, J2.00XMT) Service Manual – PDF DOWNLOAD
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Hyster E160 (J1.60XMT, J1.80XMT, J2.00XMT) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster E160 (J1.60XMT, J1.80XMT, J2.00XMT) Service Manual – PDF DOWNLOAD
Language : English
Pages : 521
Downloadable : Yes
File Type : PDF
Size: 12.7 MB
TABLE OF CONTENTS:
Hyster E160 (J1.60XMT, J1.80XMT, J2.00XMT) Service Manual – PDF DOWNLOAD
battery indicators...................................................................................... 1 INTRODUCTION........................................................................................ 1 GENERAL......................................................................................... 1 INDICATORS WITH METER MOVEMENTS................................................................. 2 BATTERY INDICATORS WITH LCD OR LED DISPLAYS..................................................... 3 Liquid Crystal Displays..................................................................... 3 Light Emitting Diode Displays............................................................... 4 CHECKS AND ADJUSTMENTS.............................................................................. 7 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARYLY MODELS........................................ 7 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS............................................ 8 Reset Potentiometer......................................................................... 8 Specific Gravity Alarm...................................................................... 8 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS......................................... 8 BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS............................................ 8 Reset Potentiometer......................................................................... 9 Discharge Potentiometer..................................................................... 9 LED DISPLAY WITH LIFT INTERRUPT................................................................. 9 CHECKING CURTIS 933-1 METER..................................................................... 9 Reset Check ................................................................................ 10 Discharge Check............................................................................. 10 Lockout Check............................................................................... 11 Hour Glass Icon............................................................................. 11 ADJUSTMENT OF CURTIS 933-1 METER................................................................ 12 CHECKING CURTIS 1215 BATTERY INDICATOR.......................................................... 12 ADJUSTING CURTIS 1215 BATTERY INDICATOR......................................................... 13 Voltage Selection........................................................................... 14 REPAIRS............................................................................................. 15 BATTERY INDICATORS.................................................................................. 15 Replacement..................................................................................... 15 CONTROLLER FOR THE BATTERY INDICATOR................................................................ 15 Replacement..................................................................................... 15 DISPLAY PANEL COMPONENTS............................................................................ 15 Brake System............................................................................................ 16 INTRODUCTION........................................................................................ 18 GENERAL......................................................................................... 18 DESCRIPTION..................................................................................... 18 REPAIRS............................................................................................. 18 SERVICE BRAKE PADS.............................................................................. 18 Removal..................................................................................... 18 Installation................................................................................ 18 SERVICE BRAKE CALIPER........................................................................... 19 Removal..................................................................................... 19 Installation................................................................................ 19 Disassembly................................................................................. 20 Assembly.................................................................................... 21 PARK BRAKE CALIPER.............................................................................. 21 Removal..................................................................................... 21 Installation................................................................................ 21 Disassembly................................................................................. 21 Assembly.................................................................................... 22 MASTER CYLINDER................................................................................. 22 Removal..................................................................................... 22 Installation................................................................................ 23 Disassembly................................................................................. 23 Assembly.................................................................................... 23 FOOT OPERATED PARK BRAKE LEVER.................................................................. 24 Removal..................................................................................... 24 Installation................................................................................ 24 ELECTRICALLY RELEASED PARK BRAKE................................................................ 26 Mechanical Operation........................................................................ 26 Removal..................................................................................... 26 Installation................................................................................ 28 ELECTRICALLY RELEASED PARK BRAKE-ELECTRICAL COMPONENTS.......................................... 29 Control Box-Removal......................................................................... 29 Control Box-Installation.................................................................... 31 Terminal Block-Removal...................................................................... 31 Terminal Block-Installation................................................................. 31 CHECKS AND ADJUSTMENTS.............................................................................. 31 PARK BRAKE ADJUSTMENT........................................................................... 31 SERVICE BRAKE ADJUSTMENT........................................................................ 32 REMOVE AIR FROM THE BRAKE SYSTEM................................................................ 32 TROUBLESHOOTING..................................................................................... 33 DC motors............................................................................................... 35 INTRODUCTION........................................................................................ 35 ELECTRIC MOTOR MAINTENANCE, GENERAL............................................................. 35 BRUSH AND COMMUTATOR INSPECTION................................................................. 35 Hydraulic Pump Motor And Traction Motor..................................................... 35 Steering Pump Motor......................................................................... 37 TROUBLESHOOTING..................................................................................... 37 TROUBLESHOOTING................................................................................. 37 Commutator Problems......................................................................... 40 BRUSH REPLACEMENT............................................................................... 42 DISASSEMBLY OF MOTORS........................................................................... 44 Traction Motor And Hydraulic Pump Motor..................................................... 44 Steering Pump Motor......................................................................... 47 ASSEMBLY OF MOTORS.............................................................................. 49 Traction Motor And Hydraulic Pump Motor..................................................... 49 Steering Pump Motor......................................................................... 49 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS.................................................. 49 TESTS FOR A DAMAGED FIELD AND ARMATURE.......................................................... 49 Test For An Open Circuit In The Armature.................................................... 50 Test For A Short–Circuit In One Armature Winding............................................ 50 Test For A Short–Circuit To Armature Shaft.................................................. 50 Test For An Open Circuit In A Field Coil.................................................... 51 Test For A Short–Circuit In A Field Coil.................................................... 51 Test For A Short–Circuit Between The Field And The Motor Case............................... 51 Brush Holder Test........................................................................... 51 electrical system....................................................................................... 52 INTRODUCTION........................................................................................ 52 GENERAL......................................................................................... 52 DESCRIPTION......................................................................................... 52 INSTRUMENT PANEL................................................................................ 52 Standard Display............................................................................ 53 Premium Display............................................................................. 53 PRINTED CIRCUIT BOARDS.......................................................................... 55 Steering Angle Control Board................................................................ 55 REPLACEMENT......................................................................................... 57 INSTRUMENT PANEL COMPONENTS..................................................................... 57 Instrument Panel Assembly................................................................... 57 Key Switch.................................................................................. 59 Battery Indicators.......................................................................... 59 Hourmeter (Standard Panel Only)............................................................. 59 Digital Display (Premium Panel Only)........................................................ 59 Indicator Lights............................................................................ 59 PRINTED CIRCUIT BOARDS.......................................................................... 59 Steering Angle Control Board................................................................ 59 Lift Pump Control Board..................................................................... 60 OTHER CONTROL COMPONENTS........................................................................ 60 Accelerator Switch Assembly................................................................. 60 Seat Switch................................................................................. 61 Parking Brake Switch........................................................................ 61 Direction Switches (Monotrol Pedal)......................................................... 61 Direction Control Switches (Steering Column)................................................ 61 CHECKS AND ADJUSTMENTS.............................................................................. 74 CONTROL POWER FUSES............................................................................. 74 CHECK ACCELERATOR SWITCH ASSEMBLY............................................................... 75 ADJUSTING STOP LIGHT SWITCH..................................................................... 75 CHECK SEAT SWITCH............................................................................... 75 ADJUSTING PARKING BRAKE SWITCH.................................................................. 76 DIRECTION SWITCHES (MONOTROL PEDAL)............................................................. 76 DIRECTION SWITCHES (STEERING COLUMN)............................................................ 76 HYDRAULIC CUT OFF SWITCH........................................................................ 76 PRINTED CIRCUIT BOARDS.......................................................................... 80 fasteners............................................................................................... 88 Frame................................................................................................... 96 INTRODUCTION........................................................................................ 98 GENERAL......................................................................................... 98 DESCRIPTION..................................................................................... 98 REPAIRS............................................................................................. 99 OVERHEAD GUARD.................................................................................. 99 Removal..................................................................................... 99 Installation................................................................................ 99 HOOD AND SEAT ASSEMBLY..........................................................................100 Removal.....................................................................................101 Installation................................................................................101 COUNTERWEIGHT...................................................................................102 Removal.....................................................................................102 Installation................................................................................103 AUXILIARY COUNTERWEIGHT.........................................................................103 Removal.....................................................................................103 Installation................................................................................104 HYDRAULIC TANK..................................................................................104 Inspection..................................................................................104 Repairs, Small Leaks........................................................................104 Repairs, Large Leaks........................................................................104 Cleaning....................................................................................104 Steam Method Of Cleaning....................................................................104 Chemical Solution Method Of Cleaning........................................................105 Additional Preparations For Repair..........................................................105 SAFETY LABELS...................................................................................105 instrument cluster......................................................................................111 INTRODUCTION........................................................................................111 GENERAL.........................................................................................111 DESCRIPTION.....................................................................................111 REPAIRS.............................................................................................115 REMOVAL AND DISASSEMBLY.........................................................................115 ASSEMBLY AND INSTALLATION.......................................................................115 large batteries.........................................................................................118 INTRODUCTION........................................................................................118 GENERAL.........................................................................................118 LEAD-ACID BATTERIES.............................................................................118 SPECIFIC GRAVITY................................................................................118 THE CHEMICAL REACTION IN A CELL.................................................................119 ELECTRICAL TERMS....................................................................................120 HOW TO SELECT THE BATTERY.......................................................................120 VOLTAGE OF A BATTERY............................................................................120 THE BATTERY AS A COUNTERWEIGHT..................................................................121 BATTERY RATINGS.................................................................................121 Kilowatt-Hours..............................................................................122 BATTERY MAINTENANCE.................................................................................122 SAFETY PROCEDURES...............................................................................122 MAINTENACE RECORDS..............................................................................123 THE NEW BATTERY.................................................................................123 HOW TO CLEAN THE BATTERY........................................................................124 HOW TO ADD WATER................................................................................124 THE HYDROMETER..................................................................................125 BATTERY TEMPERATURE.............................................................................125 CHARGING THE BATTERY............................................................................126 Types Of Battery Charges....................................................................127 Methods Of Charging.........................................................................128 Troubleshooting The Charger.................................................................128 How To Know When The Battery Is Fully Charged...............................................129 WHERE TO CHARGE THE BATTERIES...................................................................129 Equipment Needed............................................................................129 BATTERY CONNECTORS..............................................................................130 BATTERY CARE....................................................................................130 Main Control Valve......................................................................................132 INTRODUCTION........................................................................................134 GENERAL.........................................................................................134 DESCRIPTION.....................................................................................134 OPERATION.......................................................................................135 Lift Section................................................................................135 Tilt Section................................................................................136 Relief Valve................................................................................136 REPAIRS.............................................................................................136 MAIN CONTROL VALVE..............................................................................136 Removal.....................................................................................136 Installation................................................................................137 Disassembly.................................................................................140 Cleaning And Inspection.....................................................................142 Assembly....................................................................................142 CHECKS AND ADJUSTMENTS..............................................................................143 RELIEF VALVE....................................................................................143 VANE SETTINGS...................................................................................143 MAST TILT ADJUSTMENT............................................................................143 TROUBLESHOOTING.....................................................................................144 maintenance and inspection..............................................................................147 INTRODUCTION........................................................................................147 GENERAL.........................................................................................147 HOW TO MOVE A DISABLED LIFT TRUCK...............................................................147 How to Tow a Lift Truck.....................................................................147 HOW TO PUT A LIFT TRUCK ON BLOCKS...............................................................148 How to Raise the Load Wheels................................................................148 How to Raise the Steer Wheel................................................................149 MAINTENANCE SCHEDULE................................................................................149 MAINTENANCE POINTS..............................................................................149 MAINTENANCE SCHEDULE............................................................................150 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY.......................................................151 CHECKS BEFORE OPERATION.........................................................................151 Hydraulic System............................................................................151 Battery.....................................................................................152 Battery Restraint System....................................................................152 Tyres and Wheels............................................................................153 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................154 Forks.......................................................................................155 Forks, Adjustment...........................................................................155 Forks, Removal..............................................................................156 Forks, Inspection...........................................................................156 Forks, Installation.........................................................................157 Mast and Lift Chains........................................................................157 Lift Chain Adjustment.......................................................................158 CHECK THE OPERATION.............................................................................158 Gauges and Horn.............................................................................158 Control Levers and Pedals...................................................................159 Service Brakes..............................................................................159 Parking Brake...............................................................................159 Steering System.............................................................................159 EVERY 500 HOURS OR THREE MONTHS.....................................................................159 HYDRAULIC TANK BREATHER.........................................................................159 WHEEL NUT TORQUE................................................................................159 TRANSAXLE.......................................................................................159 LIFT SYSTEM OPERATION...........................................................................160 MAST............................................................................................160 LIFT CHAINS.....................................................................................161 FORKS...........................................................................................162 SAFETY LABELS...................................................................................162 BRAKE FLUID.....................................................................................162 OTHER LUBRICATION...............................................................................162 ELECTRICAL INSPECTION...........................................................................162 Contactors..................................................................................162 Motor Brushes...............................................................................165 Parking Brake...............................................................................165 2000 HOURS OR YEARLY................................................................................165 HYDRAULIC SYSTEM................................................................................165 Change the Hydraulic Oil Filter.............................................................165 Check the Hydraulic Oil Strainer............................................................166 Change the Hydraulic Oil....................................................................166 BRAKES..........................................................................................166 Adjust the Parking Brake....................................................................167 TRANSAXLE.......................................................................................167 EVERY 4000 HOURS....................................................................................168 TRANSAXLE (S2 SERIES ONLY).....................................................................168 GENERAL PROCEDURES..................................................................................168 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................168 Lift System.................................................................................168 Tilt System.................................................................................168 HOW TO CHECK THE PMT CIRCUIT....................................................................169 HOW TO CHARGE THE BATTERY.......................................................................169 HOW TO CHANGE THE BATTERY.......................................................................170 WHEELS AND TYRES....................................................................................171 GENERAL.........................................................................................171 HOW TO CHANGE THE TYRES.........................................................................171 STEER AND DRIVE WHEELS..........................................................................172 PNEUMATIC TYRES.................................................................................172 Remove the Wheel from the Lift Truck........................................................172 Tyre Sizes and Pressures....................................................................172 Remove the Tyre from the Wheel..............................................................173 Install the Tyre on the Wheel...............................................................173 PNEUMATIC SHAPED SOLID TYRES....................................................................174 Remove the Wheel from the Lift Truck........................................................174 Install the Tyre on the Wheel...............................................................175 INSTALL THE WHEEL AND TYRE......................................................................176 BATTERY SIZE SPECIFICATIONS.........................................................................177 Maintenance Schedule (2)................................................................................178 INTRODUCTION........................................................................................178 GENERAL.........................................................................................178 HOW TO MOVE A DISABLED LIFT TRUCK...............................................................178 HOW TO TOW A LIFT TRUCK.........................................................................178 HOW TO PUT A LIFT TRUCK ON BLOCKS...............................................................179 How to Raise the Load Wheels................................................................179 How to Raise The Steer Wheel................................................................180 MAINTENANCE SCHEDULE................................................................................180 MAINTENANCE POINTS..............................................................................180 Maintenance Schedule........................................................................181 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY.......................................................182 CHECKS BEFORE OPERATION.........................................................................182 Hydraulic System............................................................................182 Battery.....................................................................................183 Battery Restraint System....................................................................183 Tyres and Wheels............................................................................184 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................185 Forks.......................................................................................186 Forks, Adjustment ..........................................................................186 Forks, Removal..............................................................................187 Forks, Inspection...........................................................................187 Forks, Installation.........................................................................187 Mast and Lift Chains........................................................................188 Lift Chain Adjustments......................................................................188 CHECK THE OPERATION.............................................................................189 Gauges and Horn.............................................................................189 Control Levers and Pedals...................................................................189 Service Brakes..............................................................................189 Parking Brake...............................................................................190 Steering System.............................................................................190 EVERY 500 HOURS OR THREE MONTHS.....................................................................190 HYDRAULIC TANK BREATHER.........................................................................190 WHEEL NUT TORQUE................................................................................190 TRANSAXLE.......................................................................................190 LIFT SYSTEM OPERATION...........................................................................190 MAST............................................................................................191 LIFT CHAINS.....................................................................................192 FORKS...........................................................................................193 SAFETY LABELS...................................................................................193 BRAKE FLUID.....................................................................................193 OTHER LUBRICATION...............................................................................193 ELECTRICAL INSPECTION...........................................................................193 Contactors..................................................................................193 Motor Brushes...............................................................................196 Parking Brake...............................................................................196 2000 HOURS OR YEARLY................................................................................196 HYDRAULIC SYSTEM................................................................................196 Change the Hydraulic Oil Filter.............................................................196 Check the Hydraulic Oil Strainer............................................................196 Change the Hydraulic Oil....................................................................197 BRAKES..........................................................................................197 Adjust the Parking Brake....................................................................198 TRANSAXLE.......................................................................................198 EVERY 4000 HOURS....................................................................................199 TRANSAXLE (S2 SERIES ONLY)......................................................................199 GENERAL PROCEDURES..................................................................................199 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................199 LIFT SYSTEM.....................................................................................199 TILT SYSTEM.....................................................................................199 HOW TO CHARGE THE BATTERY.......................................................................200 HOW TO CHANGE THE BATTERY.......................................................................201 WHEELS AND TYRES....................................................................................202 GENERAL.........................................................................................202 HOW TO CHANGE THE TYRES.........................................................................202 STEER AND DRIVE WHEELS..........................................................................202 PNEUMATIC TYRES.................................................................................202 Remove the Wheel from the lift truck........................................................202 Tyre Sizes And Presures.....................................................................203 Remove the Tyre from the Wheel..............................................................203 Install The Tyre On The Wheel...............................................................204 PNEUMATIC SHAPED SOLID TYRES....................................................................205 Remove the Wheel from the lift truck........................................................205 Install the Tyre on the Wheel...............................................................205 INSTALL THE WHEEL AND TYRE......................................................................206 BATTERY SIZE SPECIFICATIONS.........................................................................207 Maintenance Schedule....................................................................................209 INTRODUCTION........................................................................................209 GENERAL.........................................................................................209 HOW TO MOVE A DISABLED LIFT TRUCK...............................................................209 How to Tow a Lift Truck.....................................................................209 HOW TO PUT A LIFT TRUCK ONTO BLOCKS.............................................................210 How to Raise the Load Wheels................................................................210 How to Raise the Steer Wheel................................................................210 MAINTENANCE SCHEDULE................................................................................212 MAINTENANCE SCHEDULE............................................................................213 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY.......................................................214 CHECKS BEFORE OPERATION.........................................................................214 Hydraulic System............................................................................214 Battery.....................................................................................215 Battery Restraint System....................................................................215 Tyres and Wheels............................................................................216 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................217 Forks.......................................................................................218 Forks, Adjustment...........................................................................218 Forks, Removal..............................................................................219 Forks, Inspection...........................................................................219 Forks, Installation.........................................................................219 Mast and Lift Chains........................................................................220 Lift Chain Adjustments......................................................................220 CHECK THE OPERATION.............................................................................221 Gauges and Horn.............................................................................221 Control Levers and Pedals...................................................................221 Service Brakes..............................................................................221 Parking Brakes..............................................................................222 Steering System.............................................................................222 EVERY 350 HOURS OR TWO MONTHS.......................................................................222 HYDRAULIC TANK BREATHER.........................................................................222 WHEEL NUT TORQUE................................................................................222 TRANSAXLE.......................................................................................222 LIFT SYSTEM OPERATION...........................................................................222 MAST............................................................................................223 LIFT CHAINS.....................................................................................224 FORKS...........................................................................................225 SAFETY LABELS...................................................................................225 BRAKE FLUID.....................................................................................225 OTHER LUBRICATION...............................................................................225 ELECTRICAL INSPECTION...........................................................................225 Contactors..................................................................................225 Motor Brushes...............................................................................228 Parking Brake...............................................................................228 2000 HOURS OR YEARLY................................................................................228 HYDRAULIC SYSTEM................................................................................228 Change the Hydraulic Oil Filter.............................................................228 Check the Hydraulic Oil Strainer............................................................228 Change the Hydraulic Oil....................................................................229 BRAKES..........................................................................................229 Adjust the Parking Brake....................................................................229 TRANSAXLE.......................................................................................230 GENERAL PROCEDURES..................................................................................231 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................231 Lift System.................................................................................231 Tilt System.................................................................................231 HOW TO CHECK THE PMT CIRCUIT....................................................................231 HOW TO CHARGE THE BATTERY.......................................................................232 HOW TO CHANGE THE BATTERY.......................................................................233 WHEELS AND TYRES....................................................................................234 GENERAL.........................................................................................234 HOW TO CHANGE THE TYRES.........................................................................235 STEER AND DRIVE WHEELS..........................................................................235 TYRE SIZES AND PRESSURES........................................................................235 PNEUMATIC TYRES.................................................................................235 Remove the Wheel from the Lift Truck........................................................235 Remove the Tyre from the Wheel..............................................................236 Install The Tyre On The Wheel...............................................................236 PNEUMATIC SHAPED SOLID TYRES....................................................................237 Remove the Wheel from the Lift Truck........................................................237 Install the Tyre on the Wheel...............................................................238 INSTALL THE WHEEL AND TYRE......................................................................239 BATTERY SIZE SPECIFICATIONS.....................................................................240 MAST (2)................................................................................................241 INTRODUCTION........................................................................................242 GENERAL.........................................................................................242 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................242 REPAIRS.............................................................................................243 FORKS...........................................................................................243 Removal.....................................................................................243 Installation................................................................................244 CARRIAGES.......................................................................................244 Removal.....................................................................................244 Repairs.....................................................................................245 Installation................................................................................245 MASTS...........................................................................................247 Removal.....................................................................................247 Disassembly.................................................................................248 Cleaning and Inspection.....................................................................253 Assembly....................................................................................256 Installation................................................................................258 LIFT CYLINDERS..................................................................................258 Removal.....................................................................................258 Disassembly.................................................................................259 Assembly....................................................................................259 Installation................................................................................259 HEADER HOSE ARRANGEMENTS........................................................................262 Installation................................................................................262 CHECKS AND ADJUSTMENTS..............................................................................271 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................271 Check The Lift Cylinders For Leaks..........................................................271 Check The Tilt Cylinders For Leaks..........................................................271 ADJUST THE TILT CYLINDERS.......................................................................271 ADJUST THE LIFT CHAINS..........................................................................272 ADJUST THE MAST.................................................................................273 ADJUST THE CARRIAGE.............................................................................274 TROUBLESHOOTING.....................................................................................275 MAST (3)................................................................................................278 INTRODUCTION........................................................................................279 GENERAL.........................................................................................279 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................279 REPAIRS.............................................................................................280 FORKS...........................................................................................280 Removal.....................................................................................280 Installation................................................................................281 CARRIAGES.......................................................................................281 Removal.....................................................................................281 Repairs.....................................................................................282 Installation................................................................................282 MASTS...........................................................................................284 Removal.....................................................................................284 Disassembly.................................................................................285 Cleaning and Inspection.....................................................................290 Assembly....................................................................................293 Installation................................................................................295 LIFT CYLINDERS..................................................................................295 Removal.....................................................................................295 Disassembly.................................................................................296 Assembly....................................................................................296 Installation................................................................................296 HEADER HOSE ARRANGEMENTS........................................................................299 Installation................................................................................299 CHECKS AND ADJUSTMENTS..............................................................................308 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................308 Check The Lift Cylinders For Leaks..........................................................308 Check The Tilt Cylinders For Leaks..........................................................308 ADJUST THE TILT CYLINDERS.......................................................................308 ADJUST THE LIFT CHAINS..........................................................................309 ADJUST THE MAST.................................................................................310 ADJUST THE CARRIAGE.............................................................................311 TROUBLESHOOTING.....................................................................................312 MAST....................................................................................................315 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................315 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................315 LIFT CYLINDERS......................................................................................318 GENERAL.........................................................................................318 DESCRIPTION.....................................................................................318 Lowering Control Valve......................................................................318 Cylinders (General).........................................................................321 Cylinders (H520-620B,H700-800A).............................................................323 Cylinders (H360-460B).......................................................................324 Cylinders (Two-Speed).......................................................................324 REPAIRS.............................................................................................325 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..........................................325 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....325 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.....................329 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...............327 DISASSEMBLY.....................................................................................327 ASSEMBLY........................................................................................329 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...................................................329 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....329 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead............329 CHEVRON PACKING.................................................................................330 LIFT CYLINDERS FOR VISTA MASTS......................................................................333 DESCRIPTION.....................................................................................333 Lowering Control Valve......................................................................335 REMOVAL.........................................................................................336 DISASSEMBLY.....................................................................................336 ASSEMBLY........................................................................................336 INSTALLATION....................................................................................337 Main Lift Cylinders.........................................................................337 Free-Lift Cylinders.........................................................................337 CHECKS AND ADJUSTMENTS..............................................................................338 CHECK FOR LEAKS IN LIFT SYSTEM..................................................................338 TROUBLESHOOTING.....................................................................................339 SPECIFICATIONS......................................................................................340 model...................................................................................................341 motor controllers.......................................................................................342 INTRODUCTION........................................................................................342 General.........................................................................................342 DESCRIPTION.........................................................................................342 Diagnostic Control Card.........................................................................342 Status Codes................................................................................344 Hand Set........................................................................................344 Instrument Panel Display........................................................................345 Hourmeter Functions.........................................................................345 Battery Indicator Functions.................................................................345 Control Card Connections........................................................................346 Schematic and Diagram...................................................................................411 WIRING SCHEMATIC WITH SCR CONTROLLED LIFT PUMP......................................................412 WIRING DIAGRAM WITH SCR CONTROLLED LIFT PUMP........................................................416 OPTIONAL WIRING WITH SCR CONTROLLED LIFT PUMP.......................................................417 WIRING SCHEMATIC WITH TMM MODULE....................................................................420 WIRING DIAGRAM WITH TMM MODULE......................................................................424 OPTIONAL WIRING WITH TMM MODULE.....................................................................425 WIRING SCHEMATIC WITH CONTACTOR CONTROLLED LIFT PUMP................................................428 WIRING DIAGRAM WITH CONTACTOR CONTROLLED LIFT PUMP..................................................432 OPTIONAL WIRING WITH CONTACTOR CONTROLLED LIFT PUMP.................................................434 OPTIONAL MAIN LIGHTS WIRING.........................................................................436 CABLE DETAILS.......................................................................................440 ELECTRICAL ARRANGEMENT WITH SCR CONTROLLED LIFT PUMP................................................441 ELECTRICAL ARRANGEMENT WITH CONTACTOR CONTROLLED LIFT PUMP..........................................442 HYDRAULIC SYSTEM ARRANGEMENT........................................................................443 HYDRAULIC SCHEMATIC.................................................................................444 Steering Housing and Control Unit.......................................................................446 INTRODUCTION........................................................................................446 GENERAL.........................................................................................446 DESCRIPTION.....................................................................................446 OPERATION.......................................................................................446 REPAIRS.............................................................................................447 STEERING HOUSING ...............................................................................447 Removal And Disassembly ........................................................................447 Cleaning .......................................................................................449 Assembly and Installation.......................................................................449 STEERING CONTROL UNIT...........................................................................449 Removal.....................................................................................449 Disassembly.................................................................................449 Cleaning....................................................................................450 Assembly....................................................................................450 Installation................................................................................450 CHECKS AND ADJUSTMENTS..............................................................................454 REMOVE AIR FROM THE SYSTEM......................................................................454 TROUBLESHOOTING.....................................................................................454 Steering System.........................................................................................455 INTRODUCTION........................................................................................455 GENERAL.........................................................................................455 OPERATION.......................................................................................455 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................456 DESCRIPTION.....................................................................................456 Removal.....................................................................................456 Installation................................................................................458 POWER STEERING PUMP AND MOTOR...................................................................459 DESCRIPTION.................................................................................459 Removal.................................................................................460 Installation............................................................................461 REPAIRS.....................................................................................462 Disassembly.............................................................................462 Assembly................................................................................462 STEERING AXLE COMPONENTS............................................................................463 GENERAL.........................................................................................463 WHEEL AND TYRE ASSEMBLY.........................................................................463 Removal.....................................................................................463 Installation................................................................................463 WHEEL HUB ASSEMBLY..............................................................................463 Removal.....................................................................................463 Installation................................................................................464 STEERING AXLE ASSEMBLY..........................................................................464 OLD STEERING SYSTEM.............................................................................464 Removal.....................................................................................464 Installation................................................................................465 ROTARY ACTUATOR (OLD SYSTEM ONLY)...............................................................466 Removal.....................................................................................466 Installation................................................................................467 Disassembly.................................................................................467 Assembly....................................................................................468 NEW STEERING SYSTEM.............................................................................469 Disassembly.................................................................................469 Cleaning ...................................................................................470 Assembly....................................................................................470 CHECKS AND ADJUSTMENTS..............................................................................472 AIR IN THE SYSTEM...............................................................................472 Check the Operation.........................................................................472 Steering Pressure...........................................................................472 TROUBLESHOOTING.....................................................................................473 Tilt Cylinders..........................................................................................476 INTRODUCTION........................................................................................479 GENERAL.........................................................................................479 DESCRIPTION.....................................................................................479 REPAIRS.............................................................................................479 REMOVAL.........................................................................................479 DISASSEMBLY.....................................................................................479 CLEANING........................................................................................479 ASSEMBLY........................................................................................479 Tilt Cylinders for the XM and XMS Models....................................................479 Tilt Cylinders with O-Ring or Single Lip Seals..............................................481 Tilt Cylinders for H700-800A and Early Model H700-920B......................................481 INSTALLATION....................................................................................481 Tilt Cylinders with Chevron Packing.........................................................481 CHECKS AND ADJUSTMENTS..............................................................................485 CHECK THE TILT CYLINDERS FOR LEAKS..............................................................485 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.........................................485 TROUBLESHOOTING.....................................................................................488 Transaxle...............................................................................................491 INTRODUCTION........................................................................................493 GENERAL.........................................................................................493 LUBRICATION.....................................................................................493 REPAIRS.............................................................................................494 REMOVAL.........................................................................................494 INSPECTION......................................................................................495 INSTALLATION....................................................................................495 S2 SERIES TRANSAXLE.................................................................................496 DISASSEMBLY.....................................................................................496 ASSEMBLY........................................................................................497 General.....................................................................................497 Ring Gear Installation......................................................................497 Intermediate Shaft Installation.............................................................497 Axle Shaft Installation.....................................................................498 Pinion Gear Installation....................................................................498 Final Assembly..............................................................................501 S1 SERIES TRANSAXLE.................................................................................503 DISASSEMBLY.....................................................................................503 ASSEMBLY........................................................................................503 TROUBLESHOOTING.....................................................................................507 Wheels and Tires........................................................................................509 WHEELS AND TYRES....................................................................................509 MOTORS (DUAL VOLTAGE 36/48).........................................................................509 MAST TILT PERFORMANCE...............................................................................509 MAST SPEEDS 19cc PUMP 1 and 2 SPEED CONTACTOR.......................................................510 MAST SPEEDS 19cc PUMP TRANSISTOR CONTROL............................................................511 MAST SPEEDS 12cc PUMP 1 and 2 SPEED CONTACTOR.......................................................512 MAST SPEEDS 12cc PUMP TRANSISTOR CONTACTOR..........................................................513 MAST/TILT DRIFT SPEEDS..............................................................................513 HYDRAULIC SYSTEM....................................................................................514 TORQUE SPECIFICATIONS...............................................................................514 ACCELERATOR POTENTIOMETER CHECKS....................................................................515 ADJUSTMENTS, EV 100 LX TRACTION CARD................................................................516 SX/SR Traction Controller Settings - Standard.......................................................517 SX/SR Traction Controller Settings - Energy Option..................................................518 SX/SR Traction Controller Settings - With or Without Auto Regen.....................................518 ADJUSTMENTS, EV 100 LX PUMP CARD....................................................................519 SX/SR Lift Pump Controller Settings.................................................................520 BATTERY SIZE SPECIFICATIONS - TYPE: LEAD ACID BATTERY ..............................................521
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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