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Hyster E20 25B, E30BS service manual – PDF DOWNLOAD
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Description
Hyster E20 25B, E30BS service manual
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Hyster E20 25B, E30BS service manual
Language : English
Pages : 373
Size : 9.61 MB
Downloadable : Yes
Format : PDF
HYSTER E20 25B, E30BS SERVICE MANUAL – PDF DOWNLOAD:
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Hyster E20 25B, E30BS service manual
- 1. Hyundai HL757-7 Wheel Loader ServiceRepair Workshop Manual DOWNLOADINSTANT DOWNLOADOriginal Factory Hyundai HL757-7 Wheel Loader Service RepairManual is a Complete Informational Book. This Service Manual haseasy-to-read text sections with top quality diagrams and instructions.Trust Hyundai HL757-7 Wheel Loader Service Repair Manual willgive you everything you need to do the job. Save time and money bydoing it yourself, with the confidence only a Hyundai HL757-7 WheelLoader Service Repair Manual can provide.Service Repair Manual Covers:SECTION 1GENERALGroup 1 Safety HintsGroup 2 SpecificationsGroup 3 Operation Checkout Record SheetSECTION 2ENGINE
- 2. Group 1 Structure and FunctionSECTION 3POWER TRAIN SYSTEMGroup 1 Structure and FunctionGroup 2 Operational Checks and TroubleshootingGroup 3 Test and AdjustmentsGroup 4 Disassembly and AssemblySECTION 4BRAKE SYSTEMGroup 1 Structure and FunctionGroup 2 Operational Checks and TroubleshootingGroup 3 Test and AdjustmentsGroup 4 Disassembly and AssemblySECTION 5STEERING SYSTEMGroup 1 Structure and FunctionGroup 2 Operational Checks and TroubleshootingGroup 3 Test and AdjustmentsGroup 4 Disassembly and AssemblySECTION 6WORK EQUIPMENTGroup 1 Structure and Function
- 3. Group 2 Operational Checks and TroubleshootingGroup 3 Test and AdjustmentsGroup 4 Disassembly and AssemblySECTION 7ELECTRICAL SYSTEMGroup 1 Component LocationGroup 2 Electrical CircuitGroup 3 Monitoring SystemGroup 4 Electrical Component SpecificationGroup 5 ConnectorsGroup 6 TroubleshootingFile Format: PDFCompatible: All Versions of Windows & MacLanguage: EnglishRequirements: Adobe PDF Reader & WinZipIts important to buy the right repair manual for your HyundaiHL757-7 Wheel Loader. It is great to have, will save you a lot andknow more about your Hyundai HL757-7 Wheel Loader, in the longrun. All pages are printable.
Table of Contents:
Hyster E20 25B, E30BS service manual
INTRODUCTION........................................................................................ 1 GENERAL......................................................................................... 1 INDICATORS WITH METER MOVEMENTS................................................................. 2 BATTERY INDICATORS WITH LCD OR LED DISPLAYS..................................................... 3 Liquid Crystal Displays..................................................................... 3 Light Emitting Diode Displays............................................................... 7 CHECKS AND ADJUSTMENTS.............................................................................. 9 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS......................................... 9 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS............................................ 9 Reset Potentiometer......................................................................... 9 Specific Gravity Alarm...................................................................... 10 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS......................................... 11 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS............................................ 11 Reset Potentiometer......................................................................... 11 Discharge Potentiometer..................................................................... 11 LED DISPLAY WITH LIFT INTERRUPT................................................................. 12 CHECKING CURTIS 933-1 METER..................................................................... 12 Reset Check................................................................................. 12 Discharge Check............................................................................. 13 Lockout Check............................................................................... 13 LED's Do Not Illuminate..................................................................... 14 Hourmeter Check............................................................................. 14 Hour Glass Icon............................................................................. 14 ADJUSTMENT OF CURTIS 933-1 METER............................................................ 14 CHECKING CURTIS 1215 BATTERY INDICATOR...................................................... 14 ADJUSTING CURTIS 1215 BATTERY INDICATOR..................................................... 15 Voltage Selection....................................................................... 16 ADJUSTING BDI OF SEM DISPLAY PANEL.......................................................... 17 REPAIRS......................................................................................... 17 BATTERY INDICATORS.......................................................................... 17 Replacement............................................................................. 17 CONTROLLER FOR THE BATTERY INDICATOR........................................................ 17 Replacement............................................................................. 17 DISPLAY PANEL COMPONENTS.................................................................... 17 REPLACING SEM DISPLAY PANEL................................................................. 17 SEM Display Panel REMOVAL................................................................... 19 Removal And Replacement................................................................. 19 INTRODUCTION........................................................................................ 24 MAGNETISM........................................................................................... 24 MAGNETISM AND PERMANENT MAGNETS................................................................. 24 ELECTROMAGNETIC FIELDS.......................................................................... 24 ELECTROMAGNETS.................................................................................. 25 ELECTROMAGNETIC INDUCTION....................................................................... 26 MAGNETIC FORCE ON A CONDUCTOR................................................................... 26 BASIC MOTORS........................................................................................ 27 MOTOR OPERATION................................................................................. 27 COMMUTATION PRINCIPLE........................................................................... 28 DIRECTION OF MOTOR ROTATION..................................................................... 28 MOTOR SPEED..................................................................................... 28 MOTOR TORQUE.................................................................................... 29 COUNTER ELECTROMOTIVE FORCE..................................................................... 29 TYPICAL MOTOR................................................................................... 29 TYPES OF MOTORS................................................................................. 29 Permanent–Magnet............................................................................ 29 Series Wound................................................................................ 30 Parallel or Shunt Wound..................................................................... 31 Compound Wound.............................................................................. 31 MOTOR INSULATION CLASS.......................................................................... 32 STORAGE......................................................................................... 32 HANDLING........................................................................................ 32 BREAK–IN OPERATION.............................................................................. 32 CLEANING........................................................................................ 33 BASIC REPAIR GUIDELINES......................................................................... 33 BEARINGS, SEALS AND LUBRICATION................................................................. 34 BRUSHES AND BRUSH HOLDERS....................................................................... 34 ARMATURE........................................................................................ 35 COMMUTATOR...................................................................................... 35 Description................................................................................. 35 SATISFACTORY SURFACE............................................................................ 36 STREAKING AND THREADING SURFACE................................................................. 37 GROOVING ON SURFACE............................................................................. 38 COPPER DRAG ON SURFACE.......................................................................... 40 OVERHEATING..................................................................................... 40 FIELD ASSEMBLY.................................................................................. 42 INSPECTION CHECKLIST............................................................................ 42 CHECKING AND REPLACING MOTOR BRUSHES............................................................ 42 Inspecting Brushes.......................................................................... 42 INSPECT THE COMMUTATOR.......................................................................... 43 REPLACING BRUSHES............................................................................... 43 SEATING BRUSHES (STONING PROCEDURE)............................................................. 43 CHECK THE MOTORS FOR OPENS, GROUNDS AND SHORTS.................................................. 44 Check The Motor For Opens................................................................... 44 Check The Motor For Grounds................................................................. 44 Check The Motor For Shorts.................................................................. 44 COMMUTATOR INSPECTION........................................................................... 46 POLISHING COMMUTATOR............................................................................ 47 TURNING COMMUTATOR.............................................................................. 47 UNDERCUTTING COMMUTATOR......................................................................... 47 SLOT RAKING AND BRUSHING COMMUTATOR............................................................. 47 ELECTRICAL SYSTEM CABLING DIAGRAM................................................................... 49 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM 36/48 VOLT (EARLY).............................................. 50 ELECTRICAL SYSTEM WIRING DIAGRAM 36/48 VOLT (EARLY)................................................. 52 ELECTRICAL SYSTEM SCHEMATIC DIAGRAM 36/48 VOLT (LATER).............................................. 54 ELECTRICAL SYSTEM WIRING DIAGRAM 36/48 VOLT (LATER)................................................. 56 HYDRAULIC SYSTEM SCHEMATIC.......................................................................... 58 INTRODUCTION........................................................................................ 59 General......................................................................................... 59 Description..................................................................................... 59 REPAIRS............................................................................................. 59 Removal Of The Drive Axle (E20-30BS)............................................................ 59 Installation.................................................................................... 61 Removal Of The Drive Axle (E20-30BH)............................................................ 61 Installation.................................................................................... 62 Wheels And Tires................................................................................ 63 Removal Of The Speed Reducer And Differential................................................... 64 Disassembly..................................................................................... 67 Assembly........................................................................................ 68 Installation Of The Drive Assembly.............................................................. 70 TROUBLESHOOTING..................................................................................... 72 ELECTRICAL CHECKS AND ADJUSTMENTS FOR SitDrive) ELECTRICAL LIFT TRUCKS.............................. 73 GENERAL......................................................................................... 73 CONTROL AND POWER FUSES......................................................................... 78 CONTROL CARD ADJUSTMENTS........................................................................ 79 Adjusting Creep Speed, "CREEP'.............................................................. 81 Adjusting Controlled Acceleration, "C/A" ................................................... 81 Adjusting Current Limit, "C/L".............................................................. 82 Adjust "1A TIME"............................................................................ 83 Adjust 1A Drop Out, "1A D.O"................................................................ 85 Adjust Plugging, "PLUG"..................................................................... 85 Ramp Start.................................................................................. 85 Adjust Field Weakening Pick Up and Drop Out, "F.W.P.U." And "F.W.D.O."...................... 85 Adjust "REGEN C/L" (Current Limit).......................................................... 86 Adjust "REGEN D.O." (Drop Out).............................................................. 86 PROPORTIONAL CONTROL (J25-35A Only)............................................................. 89 SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS......................................................... 90 SCR CONTROL, SINGLE PUMP MOTOR.................................................................. 90 Accelerator Card (E-20-100B, J40-60AS Only)................................................. 91 Circuit Description For Accelerator Card Used With A Seat Switch............................ 92 Accelerator "START" (IC3)................................................................... 93 Accelertor "1A TIME" (IC2).................................................................. 93 Circuit Description For Accelerator Card Used With A Seat Brake............................. 93 Accelerator "START" (IC3)................................................................... 94 Accelerator "1A TIME" (IC1 and IC2)......................................................... 94 CHECK THE ACCELERTOR CARD................................................................... 94 ADJUSTING THE ACCELERATOR CARD.............................................................. 94 THE POTENTIOMETERS AND CONTOL SWITCHES.......................................................... 94 Steering Potentiometer (J25-35A Only)....................................................... 94 Accelerator Potentiometer And Start Switch (E20-120XL And J25-60XL Only).................... 96 Accelerator Potentiometer And Direction Switch.............................................. 97 Adjusting Start Switch...................................................................... 98 "FORWARD" And "REVERSE" Switch (MONOTROL) (Earlier Production Lift Trucks).................. 98 Direction Switches (MONOTROL) (Later Production Lift Trucks)................................ 99 "FORWARD" And "REVERSE" Switch (Steering Column)............................................100 Hydraulic Pump Switch.......................................................................100 Replace The Key Switch......................................................................100 Adjust The Seat Switch......................................................................100 Adjust The Brake Switch.....................................................................101 Parking Brake Switch........................................................................101 Rocker Switch...............................................................................102 HYDRAULIC PUMP SOFT START (E100-120B Only) (72/80 Volt Only)....................................103 ELECTRICAL WARNING DEVICES..........................................................................104 GENERAL.........................................................................................104 DESCRIPTION.....................................................................................104 Operator Controlled Horns...................................................................104 System Warning Lights, Buzzers and Bells....................................................104 Reverse Warning Horns.......................................................................105 Warning Lights..............................................................................105 REPLACEMENT.....................................................................................106 General.....................................................................................106 Replacing Horns or Bells....................................................................106 Replacing Horn Relay or Buzzer..............................................................106 Replacing Warning Lights....................................................................106 Light Assemblies............................................................................107 Replacing Flashing Units....................................................................107 INTRODUCTION........................................................................................108 GENERAL.........................................................................................108 PRINCIPLES OF OPERATION.............................................................................108 LIFT TRUCK CONTROL..............................................................................108 ELECTRONIC SPEED CONTROLS.......................................................................109 The Silicon Controlled Rectifier (SCR)......................................................109 The Traction Circuit That Operates With Pulses..............................................109 The SCR 1 OFF Circuit.......................................................................113 THE CONTROL CARD FOR THE TRACTION CIRCUIT.......................................................113 SRO Circuit.................................................................................114 Pulse Monitor Trip (PMT)....................................................................114 Control Card Adjustments....................................................................115 C/L (Current Limit).........................................................................115 Plug........................................................................................115 Creep.......................................................................................116 C/A (Controlled Acceleration)...............................................................116 THERMAL PROTECTION..............................................................................116 THE 1A CIRCUIT..................................................................................116 FIELD WEAKENING.................................................................................117 RAMP START......................................................................................118 ACCELERATOR CONTROL.............................................................................118 CONTACTORS AND ELECTRONIC DRIVERS...............................................................118 The Electronic Drivers......................................................................118 Contactors..................................................................................118 CIRCUIT PROTECTION..............................................................................120 Current Limit...............................................................................120 Thermal Protection..........................................................................120 Traction Circuit Fuse.......................................................................120 SEQUENCE OF OPERATION...........................................................................120 INTRODUCTION........................................................................................131 GENERAL.........................................................................................131 SRO CIRCUIT AND PMT CIRCUIT.........................................................................132 STATIC RETURN TO OFF(SRO) CIRCUIT...............................................................132 PULSE MONITOR TRIP (PMT)........................................................................132 THE SEQUENCE OF OPERATION.......................................................................133 TROUBLESHOOTING.....................................................................................133 GENERAL PROCEDURES..............................................................................133 FAULT IN THE CONTROL CIRCUIT................................................................136 CHECKS AND REPAIRS..................................................................................151 GENERAL.........................................................................................151 CHECK FOR THE CORRECT OPERATION.................................................................151 CONTROL AND POWER FUSES.........................................................................152 CONTROL CARD....................................................................................152 Removal.....................................................................................154 Installation................................................................................154 SCRs............................................................................................154 An SCR "QUICK REF"..........................................................................154 Checking An SCR.............................................................................154 The SCR 1 Assembly..........................................................................156 Thermal Sensor..............................................................................156 Checking SCR 1..............................................................................156 Replacing The SCR 1 Assembly................................................................156 THE INDUCTOR AND CAPACITOR ASSEMBLY (THE "OFF" CIRCUIT FOR SCR 1)...............................157 Checking The Transformer and Inductor Assembly..............................................157 Checking the Supressors for the SCR 2 and SCR 5.............................................157 Checking the SCR 2 and SCR 5................................................................158 Replacing the SCR 2 and SCR 5...............................................................158 Checking The Capacitor C1...................................................................158 D3 And D4 Heat Sink Assembly................................................................158 Checking The Diodes D3 and D4...............................................................158 Replacing The Diodes D3 and D4..............................................................159 MOTOR CURRENT SENSOR............................................................................159 THE ELECTRONIC DRIVER MODULE....................................................................159 CONTACTORS......................................................................................160 "FORWARD" And "REVERSE" Contactors..........................................................160 CONTACTOR REPAIR................................................................................161 Remove A Contactor Assembly.................................................................161 Contactor Contacts..........................................................................161 Coil........................................................................................161 CHECK THE PMT CIRCUIT...........................................................................162 INTRODUCTION........................................................................................164 GENERAL.........................................................................................164 DESCRIPTION.....................................................................................164 DISASSEMBLY AND ASSEMBLY............................................................................165 OVERHEAD GUARD..................................................................................165 Removal.....................................................................................165 Installation................................................................................165 SEAT ASSEMBLY...................................................................................165 COUNTERWEIGHT...................................................................................165 Removal.....................................................................................166 Installation................................................................................166 HYDRAULIC TANK REPAIRS..........................................................................166 Small Leaks.................................................................................166 Large Leaks.................................................................................167 Steam Method Of Cleaning....................................................................167 Chemical Solution Method of Cleaning........................................................167 Other Methods...............................................................................167 LABEL REPLACEMENT...............................................................................168 INTRODUCTION........................................................................................170 DESCRIPTION.....................................................................................170 OPERATION.......................................................................................170 Flow Control Valve..........................................................................172 Relief Valve................................................................................172 REPAIRS.............................................................................................173 REMOVAL.........................................................................................173 DISASSEMBLY.....................................................................................173 CLEANING........................................................................................175 INSPECTION......................................................................................175 ASSEMBLY........................................................................................176 INSTALLATION....................................................................................177 CHECKS AND ADUSTMENTS...............................................................................178 CHECK THE OUTPUT OF THE PUMP....................................................................178 CHECK FOR AIR IN THE HYDRAULIC SYSTEM...........................................................178 TROUBLESHOOTING.....................................................................................180 INTRODUCTION........................................................................................183 General.........................................................................................183 Description.....................................................................................183 The Control Valve...............................................................................185 REPAIRS.............................................................................................190 Hydraulic Pump..................................................................................190 Main Control Valve..............................................................................192 Hydraulic Pump Contactor........................................................................197 Contactor Repair................................................................................197 CHECKS AND ADJUSTMENTS..............................................................................198 Adjusting The Pressure Relief Valve.............................................................198 Adjustment Of The Control Linkage...............................................................198 Hydraulic Pump Switch...........................................................................198 TROUBLESHOOTING.....................................................................................199 INTRODUCTION........................................................................................201 GENERAL.........................................................................................201 DESCRIPTION.....................................................................................201 OPERATION.......................................................................................201 Pump........................................................................................201 Relief Valve................................................................................202 REPAIRS.............................................................................................203 REMOVAL.........................................................................................203 DISASSEMBLY.....................................................................................203 ASSEMBLY........................................................................................204 INSTALLATION....................................................................................205 CHECKS AND ADJUSTMENTS..............................................................................205 CHECKING THE RELIEF PRESSURE OF THE RELIEF VALVE................................................205 Lift Trucks With Internal Combustion Engines................................................205 Electric Lift Trucks........................................................................205 Electric Lift Trucks With Adjustable Relief Valve...........................................206 SPECIFICATIONS......................................................................................207 TROUBLESHOOTING.....................................................................................207 INTRODUCTION........................................................................................208 GENERAL.........................................................................................208 LEAD-ACID BATTERIES.............................................................................208 SPECIFIC GRAVITY................................................................................209 CHEMICAL REACTION IN A CELL.....................................................................209 ELECTRICAL TERMS................................................................................210 HOW TO SELECT THE BATTERY.......................................................................210 VOLTAGE OF A BATTERY............................................................................210 THE BATTERY AS A COUNTERWEIGHT..................................................................211 BATTERY RATINGS.................................................................................211 Kilowatt-Hours..............................................................................212 BATTERY MAINTENANCE.................................................................................212 SAFETY PROCEDURES...............................................................................212 MAINTENCE RECORDS...............................................................................213 THE NEW BATTERY.................................................................................213 HOW TO CLEAN THE BATTERY........................................................................214 HOW TO ADD WATER................................................................................214 THE HYDROMETER..................................................................................215 BATTERY TEMPERATURE.............................................................................215 CHARGING THE BATTERY............................................................................216 Types Of Battery Charges....................................................................217 Methods Of Charging.........................................................................218 Troubleshooting The Charger.................................................................218 How to Know When The Battery Is Fully Charged...............................................219 WHERE TO CHARGE THE BATTERIES...................................................................219 Equipment Needed............................................................................219 BATTERY CONNECTORS..............................................................................220 BATTERY CARE....................................................................................220 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................222 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................222 LIFT CYLINDERS......................................................................................225 GENERAL.........................................................................................225 DESCRIPTION.....................................................................................225 Lowering Control Valve......................................................................225 Cylinders (General).........................................................................228 Cylinders (H520-620B,H700-800A).............................................................230 Cylinders (H360-460B).......................................................................231 Cylinders (Two-Speed).......................................................................231 REPAIRS.............................................................................................232 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..........................................232 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....232 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.....................236 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...............234 DISASSEMBLY.....................................................................................234 ASSEMBLY........................................................................................236 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...................................................236 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....236 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead............236 CHEVRON PACKING.................................................................................237 LIFT CYLINDERS FOR VISTA MASTS......................................................................240 DESCRIPTION.....................................................................................240 Lowering Control Valve......................................................................242 REMOVAL.........................................................................................243 DISASSEMBLY.....................................................................................243 ASSEMBLY........................................................................................243 INSTALLATION....................................................................................244 Main Lift Cylinders.........................................................................244 Free-Lift Cylinders.........................................................................244 CHECKS AND ADJUSTMENTS..............................................................................245 CHECK FOR LEAKS IN LIFT SYSTEM..................................................................245 TROUBLESHOOTING.....................................................................................246 SPECIFICATIONS......................................................................................247 INTRODUCTION........................................................................................248 GENERAL.........................................................................................248 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)...............................250 FULL FREE-LIFT MASTS............................................................................250 THREE-STAGE MASTS...............................................................................252 FOUR-STAGE MASTS................................................................................253 SEQUENCE VALVE..................................................................................253 INTRODUCTION........................................................................................255 REPAIRS.............................................................................................255 Forks...........................................................................................255 Carriage........................................................................................255 Uprights........................................................................................257 CHECKS AND ADJUSTMENTS..............................................................................262 Checking For Leaks In The Lift System...........................................................262 Adjusting The Tilt Cylinder Stroke And Backward Tilt Angle......................................263 Upright Adjustments.............................................................................264 TROUBLESHOOTING.....................................................................................268 INTRODUCTION........................................................................................269 GENERAL.........................................................................................269 DESCRIPTION.....................................................................................269 REPAIRS.............................................................................................269 REMOVAL AND DISASSEMBLY.........................................................................269 CLEANING .......................................................................................270 ASSEMBLY........................................................................................270 CHECKS AND ADJUSTMENTS..............................................................................270 CHECKS..........................................................................................270 INTRODUCTION........................................................................................271 General.........................................................................................271 Description.....................................................................................271 REPAIRS.............................................................................................272 Parking Brake Assembly..........................................................................272 ADJUSTMENTS.........................................................................................273 Adjustment of the Hand Brake Linkage............................................................273 Adjustment of the Linkage for the Hand and Seat Brake...........................................273 INTRODUCTION........................................................................................274 General.........................................................................................274 Moving A Disabled Lift Truck....................................................................274 MAINTENANCE SCHEDULE................................................................................274 MAINTENANCE PROCEDURES..............................................................................276 Every 8 Hours or Daily..........................................................................276 Hydraulic System............................................................................276 Battery.....................................................................................277 Tires.......................................................................................277 Lift Mechanism..............................................................................277 Forks.......................................................................................277 Lift Chain..................................................................................278 Upright.....................................................................................278 Carriage....................................................................................279 Load Backrest Extension.....................................................................279 Brakes......................................................................................279 Guages and Horn.............................................................................280 Every 350 Hours or Two Months...................................................................280 Brake Fluid.................................................................................280 Hydraulic Tank Breather.....................................................................281 Differential and Speed Reducer..............................................................281 Uprights....................................................................................281 Forks.......................................................................................281 Electrical Inspection.......................................................................283 Every 2000 Hours or Yearly......................................................................285 Hydraulic System............................................................................285 Wheel Bearings..............................................................................285 Brake Shoes.................................................................................285 WHEELS AND TIRES................................................................................286 CHANGING THE BATTERY............................................................................288 INTRODUCTION........................................................................................289 NOMENCLATURE, THREADS...........................................................................289 STRENGTH IDENTIFICATION.........................................................................290 TABLE 1. BOLTS AND SCREWS...........................................................................290 TABLE 2. STUDS AND NUTS.............................................................................291 TABLE 3. TORQUE NUTS................................................................................292 TABLE 4. TORQUE NUTS WITH NYLON INSERT..............................................................293 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...........................................................294 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.........................................................295 INTRODUCTION........................................................................................298 General.........................................................................................298 Description And Operation.......................................................................298 REPAIRS.............................................................................................298 Removal And Disassembly.........................................................................298 CHECKS AND ADJUSTMENTS..............................................................................301 Checks..........................................................................................301 Adjustments.....................................................................................301 TROUBLESHOOTING.....................................................................................302 INTRODUCTION........................................................................................303 GENERAL.........................................................................................303 DESCRIPTION.....................................................................................303 OPERATION.......................................................................................303 REPAIRS.............................................................................................303 STEERING WHEEL AND COLUMN ASSEMBLY..............................................................303 TYPE "A" STEERING COLUMN ASSEMBLY...............................................................305 Removal And Disassembly.....................................................................305 Assembly And Installation...................................................................305 TYPE "A" STEERING COLUMN........................................................................306 TYPE "A" STEERING COLUMN........................................................................307 TYPE "B" STEERING COLUMN........................................................................308 Removal And Disassembly.....................................................................308 Assembly And Installation...................................................................308 TYPE "B" STEERING COLUMN........................................................................309 Disassembly of Steering Control Unit........................................................310 Cleaning of Steering Control Unit...........................................................310 Assembly of Steering Control Unit...........................................................312 CHECKS AND ADJUSTMENTS..............................................................................315 REMOVE AIR FROM THE SYSTEM......................................................................315 TROUBLESHOOTING.....................................................................................316 MANUAL STEERING SYSTEM (E20-30BS)...................................................................317 System Description..............................................................................318 Steering Wheel Assembly.........................................................................318 Steering Column Assembly........................................................................319 Steering Gear Assembly..........................................................................321 Tie Rods And Drag Link..........................................................................327 Steering Axle Assembly..........................................................................328 Wheel Hubs And Spindles.........................................................................333 POWER STEERING SYSTEM...............................................................................336 System Description..............................................................................336 Steering Wheel And Column Assembly..............................................................337 Steering Control Unit...........................................................................339 Power Steering Motor And Pump...................................................................339 Power Steering Axle Assembly....................................................................340 Steering Cylinder...............................................................................341 Wheel Hubs And Spindles.........................................................................345 Inspection Requirements.........................................................................345 Manual Steering Checks And Adjustments..........................................................350 E20-30BH STEERING SYSTEM SUPPLEMENT.................................................................352 MANUAL STEERING SYSTEM..............................................................................352 Steering Axle Assembly..........................................................................352 Wheel Hubs And Spindles.........................................................................355 Steer Wheel And Tire............................................................................357 POWER STEERING SYSTEM...............................................................................358 Power Steering Assembly.........................................................................358 Steering Cylinder...............................................................................359 Wheel Hubs And Spindles.........................................................................360 Checks And Adjustments..........................................................................361 INTRODUCTION........................................................................................363 GENERAL.........................................................................................363 DESCRIPTION.....................................................................................363 REPAIRS.............................................................................................363 REMOVAL.........................................................................................363 DISASSEMBLY.....................................................................................363 CLEANING........................................................................................363 ASSEMBLY........................................................................................363 Tilt Cylinders with O-Rings or Single Lip Seals.............................................363 Tilt Cylinders for the XM and XMS Models....................................................364 Tilt Cylinders for H700 800A and Early Model H700 920B......................................366 INSTALLATION....................................................................................366 Tilt Cylinders Using Chevron Packing........................................................367 CHECKS AND ADJUSTMENTS..............................................................................369 CHECK THE TILT CYLINDERS FOR LEAKS..............................................................369 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.........................................369 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS............................................370 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS...........................................371 TROUBLESHOOTING.....................................................................................373
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
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