Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster E25 35XM₂, E40XMS₂ service manual – PDF DOWNLOAD
Original price was: $92.95.$32.95Current price is: $32.95.
Hyster E25 35XM₂, E40XMS₂ service manual
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster E25 35XM₂, E40XMS₂ service manual
File Details:
Hyster E25 35XM₂, E40XMS₂ service manual
Language : English
Pages : 590
Size : 17.72 MB
Downloadable : Yes
Format : PDF
HYSTER E25 35XM₂, E40XMS₂ SERVICE MANUAL – PDF DOWNLOAD:
Image Preview:
Description:
Hyster E25 35XM₂, E40XMS₂ service manual
- BRAKE SYSTEM, GENERAL This section has a description and the service procedures for the brake systems. The service brake system includes the following parts: master cylinder, brake shoes, wheel cylinders, pedal and linkage. See FIGURE 1. The parking brake includes the pedal, linkage and cables to operate the service brake shoes. See FIGURE 9. Some units have an additional seat brake as shown in FIGURE 11. This seat brake is connected to the armature of the traction motor. DESCRIPTION AND OPERATION (See FIGURE 1. and FIGURE 2.) Service Brakes A service brake assembly is installed on the mounts at each end of the drive axle. The parts of the service brake assembly are shown in FIGURE 1. and FIGURE 3. When the brake pedal is pushed, fluid pressure from the master cylinder causes the pistons in the wheel cylinders to extend. The pistons push the brake shoes against the drums.
- FIGURE 1. SERVICE BRAKE SYSTEM 1. BRAKE PEDAL 2. MASTER CYLINDER 3. BRAKE ASSEMBLY 4. BRAKE FLUID RESERVOIR 12836 1 2 3 4 The clearance between the brake shoes and the hub is adjusted automatically. An adjuster linkage turns the adjuster wheel to adjust the clearance. When the lift truck moves in the REVERSE direction and the brakes are applied, the rear brake shoe and the adjuster links move with the drum. This linkage moves the adjuster lever to rotate the adjuster wheel. The adjuster wheel can turn only when there is clearance between the lining of the brake shoe and the hub. The adjuster wheel can also be turned with a tool. A slot in the back plate gives access to the adjuster wheel. Master Cylinder The master cylinder is designed for a dual circuit system
- . The master cylinder has two separate pistons that operate in the single bore of the master cylinder. The reservoir for the fluid is pressed into the two ports on top of the master cylinder and held in position by seals. When the brake pedal is pushed, the push rod moves the piston assemblies. The operation of the master cylinder is described in FIGURE 2. If a failure occurs in one of the dual circuits, the other circuit will apply one of the service brakes. This failure will cause the brake pedal to travel farther when the brakes are applied, but the service brakes on one drive wheel will operate.
- This failure of one of the brake circuits can cause the lift truck to turn toward the drive wheel with the good brake when the brakes are applied. The operator must control the direction of the lift truck with the steering when the brakes are applied during this condition. The reservoir is equipped with an indicator for low fluid level. A float in the reservoir moves up and down with the fluid level.
- When the fluid level is low, a magnet on the float activates a switch in the bottom of the reservoir. This switch energizes a warning light on the display panel. Parking Brake The parking brake system uses the service brake shoes. See FIGURE 5. Additional linkage activates the parking brake system. When the parking brake pedal is moved to apply the parking brake, the cables and linkage expand the brake shoes against the drum. The design of the parking brake linkage adjusts the tension in each cable so that the parking brake is applied evenly to the left and right brakes
Table of Contents:
Hyster E25 35XM₂, E40XMS₂ service manual
INTRODUCTION............................................................................................................................ 1 BRAKE SYSTEM, GENERAL............................................................................................................... 1 DESCRIPTION AND OPERATION........................................................................................................... 1 Service Brakes.................................................................................................................. 1 Master Cylinder................................................................................................................. 1 Parking Brake................................................................................................................... 1 SERVICE BRAKES...................................................................................................................... 3 Removal And Disassembly......................................................................................................... 3 Cleaning........................................................................................................................ 4 Inspection...................................................................................................................... 5 Assembly And Installation....................................................................................................... 5 MASTER CYLINDER..................................................................................................................... 8 Removal......................................................................................................................... 8 Cleaning And Inspection......................................................................................................... 8 Repair.......................................................................................................................... 8 Installation.................................................................................................................... 8 PARKING BRAKE....................................................................................................................... 10 Removal And Disassembly......................................................................................................... 10 Assembly And Installation....................................................................................................... 11 REPLACE THE PARKING BRAKE SWITCH.................................................................................................... 12 CHECKS AND ADJUSTMENTS.............................................................................................................. 13 Remove The Air From The Brake System............................................................................................ 13 Adjust The Service Brakes....................................................................................................... 13 Adjust The Brake Pedal.......................................................................................................... 14 Adjust The Master Cylinder...................................................................................................... 14 Adjust The Parking Brake........................................................................................................ 14 Adjust The Parking Brake Switch................................................................................................. 14 Test The "Parking Brake Not Applied" Warning.................................................................................... 14 Adjust The Seat Brake........................................................................................................... 14 TORQUE SPECIFICATIONS................................................................................................................... 16 TROUBLESHOOTING......................................................................................................................... 16 WHEELS AND TIRES ....................................................................................................................... 19 COUNTERWEIGHTS.......................................................................................................................... 19 HYDRAULIC SYSTEM........................................................................................................................ 19 CAPACITIES.............................................................................................................................. 19 BATTERY SPECIFICATIONS.................................................................................................................. 20 BATTERY HEIGHT SPECIFICATIONS (Hoods and Battery Types)................................................................................. 20 MAXIMUM CARRIAGE AND TILT CREEP RATES................................................................................................... 21 E25-40XM MAST SPEEDS (36 & 48 VOLT) Americas............................................................................................ 21 CONTACTOR CONTROLLED 184 mm (7.25 in) MOTOR & 19 cc (1.16 in3) LIFT PUMP*........................................................... 21 TRAN. OR SCR CONTROLLED 184 mm (7.25 in) MOTOR & 19 cc (1.16 in3) LIFT PUMP*........................................................ 22 CONTACTOR CONTROLLED 184 mm (7.25 in) MOTOR & 12 cc (0.73 in3) LIFT PUMP............................................................ 23 CONTACTOR CONTROLLED 169 mm (6.65 in) MOTOR & 12 cc (0.73 in3) LIFT PUMP*........................................................... 24 E1.50-2.00XM MAST SPEEDS (48 VOLT) Europe............................................................................................... 25 CONTACTOR CONTROLLED 184 mm MOTOR & 19 cc LIFT PUMP*................................................................................ 25 CONTACTOR CONTROLLED 169 mm MOTOR & 12 cc LIFT PUMP*................................................................................ 26 TRANSISTOR CONTROLLED 184 mm MOTOR & 19 cc LIFT PUMP*............................................................................... 27 TRANSISTOR CONTROLLED 169 mm MOTOR & 12 cc LIFT PUMP*............................................................................... 28 E25-40XM, E25-40XM2 MAST SPEEDS (3/99) Americas......................................................................................... 29 184 mm (7.25 in) MOTOR & 19 cc (1.16 in3) LIFT PUMP*................................................................................ 29 184 mm (7.25 in) MOTOR & 12 cc (0.73 in3) LIFT PUMP*................................................................................ 30 169 mm (6.65 in) MOTOR & 12 cc (0.73 in3) LIFT PUMP*................................................................................ 31 E1.50-1.75XM E2.00XMS MAST SPEEDS (3/99) Europe......................................................................................... 32 184 mm MOTOR & 19 cc LIFT PUMP*..................................................................................................... 32 169 mm MOTOR & 12 cc LIFT PUMP*..................................................................................................... 33 TORQUE SPECIFICATIONS................................................................................................................... 33 REFERENCE TABLE......................................................................................................................... 35 INTRODUCTION............................................................................................................................ 36 ELECTRIC MOTOR MAINTENANCE, GENERAL................................................................................................. 36 BRUSH AND COMMUNICATOR INSPECTION................................................................................................... 36 Hydraulic Pump Motor And Traction Motor......................................................................................... 36 Steering Pump Motor............................................................................................................. 38 BRUSH WEAR REPLACEMENT GUIDE............................................................................................................ 38 Commutator Problems................................................................................................................. 40 BRUSH REPLACEMENTS.................................................................................................................. 42 DISASSEMBLY OF MOTORS............................................................................................................... 44 Traction Motor And Hydraulic Pump Motor......................................................................................... 44 Steering Pump Motor............................................................................................................. 50 ASSEMBLY OF MOTORS.................................................................................................................. 52 Traction Motor And Hydraulic Pump Motor ........................................................................................ 52 Steering Pump Motor............................................................................................................. 52 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS...................................................................................... 52 TESTS FOR A DAMAGED FIELD AND ARMATURE.............................................................................................. 53 Test For An Open Circuit In The Armature........................................................................................ 53 Test For A Short-Circuit In One Armature Winding................................................................................ 53 Test For A Short-Circuit To Armature Shaft...................................................................................... 54 Test For An Open Circuit In A Field Coil........................................................................................ 54 Test For A Short-Circuit In A Field Coil........................................................................................ 54 Test For A Short-Circuit Between The Field And The Motor Case................................................................... 55 Brush Holder Test............................................................................................................... 55 TROUBLESHOOTING......................................................................................................................... 55 FIGURE 1. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (E25-65XM2).................................................. 57 FIGURE 2. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (E25-65XM2)............................................................ 58 FIGURE 3. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (E25-65XM2).............................................................. 59 FIGURE 4. WIRING DIAGRAM - COMMON CONCEPTS (E25-65XM2) (SEM)............................................................................ 60 FIGURE 5. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLER (E25-65XM2)................................................................. 61 FIGURE 6. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (E25-65XM2)................................... 62 FIGURE 7. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (N30XMH2).................................................... 63 FIGURE 8. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (N30XMH2).............................................................. 64 FIGURE 9. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (N30XMH2)................................................................ 65 FIGURE 10. WIRING DIAGRAM - COMMON COMPONENTS (N30XMH2)................................................................................. 66 FIGURE 11. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLERS (N30XMH2)................................................................. 67 FIGURE 12. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (N30XMH2).................................... 68 FIGURE 13. ELECTRICAL WIRING CONNECTORS (E25-65XM2) (N30XMH2)........................................................................... 69 FIGURE 14. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (J40-65XM2)................................................. 70 FIGURE 15. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (J40-65XM2)........................................................... 71 FIGURE 16. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (J40-65XM2)............................................................. 72 FIGURE 17. WIRING DIAGRAM - COMMON COMPONENTS (J40-65XM2)............................................................................... 73 FIGURE 18. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLER (J40-65XM2)................................................................ 74 FIGURE 19. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (J40-65XM2).................................. 75 FIGURE 20. ELECTRICAL WIRING CONNECTORS (J40-65XM2)..................................................................................... 76 FIGURE 21. STEERING COLUMN WIRING DETAIL (E25-40XM2).................................................................................... 77 FIGURE 22. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS (E25-40XM2).............................................................. 78 FIGURE 23. TRUCK WIRING (E25-40XM2)..................................................................................................... 79 FIGURE 24. TRUCK POWER CABLES (E25-40XM2)............................................................................................... 80 FIGURE 25. STEERING COLUMN WIRING DETAIL (E40-65XM2, J40-65XM2 AND N30XMH2)............................................................. 81 FIGURE 26. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS (E40-65XM2, J40-65XM2 AND N30XMH2)....................................... 82 FIGURE 27. TRUCK WIRING (E40-65XM2, J40-65XM2 AND N30XMH2).............................................................................. 83 FIGURE 28. TRUCK POWER CABLES (E40-65XM2, J40-65XM2 AND N30XMH2)........................................................................ 84 FIGURE 29. PANEL WIRING WITH SR (SEM) AND SP MOTOR CONTROLLERS.......................................................................... 85 FIGURE 30. PANEL WIRING WITH SR (SEM) MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL....................................................... 86 FIGURE 31. SR (SEM) AND SP MOTOR CONTROLLERS............................................................................................ 87 FIGURE 32. SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL OF PUMP MOTOR................................................................ 88 FIGURE 33. (SEM) DISPLAY PANELS......................................................................................................... 89 FIGURE 34. (SEM) DISPLAY PANEL CONNECTIONS AND MOUNTING................................................................................. 90 FIGURE 35. LIGHTING SCHEMATIC DIAGRAM (E25-65XM2, J40-65XM2 AND N30XMH2)................................................................ 91 FIGURE 36. LIGHT WIRING DIAGRAM (E25-40XM2)............................................................................................. 93 FIGURE 37. LIGHT WIRING DIAGRAM (E45-65XM2 AND N30XMH2)................................................................................. 95 INTRODUCTION............................................................................................................................ 98 GENERAL............................................................................................................................. 98 DESCRIPTION......................................................................................................................... 98 REPAIRS................................................................................................................................. 98 DRIVE UNIT ASSEMBLY................................................................................................................. 98 Remove The Complete Drive Unit Assembly As A Unit............................................................................... 98 Traction Motor, Removal......................................................................................................... 99 Drive Unit And Speed Reducer, Removal...........................................................................................100 Disassembly Of The Drive Axle...................................................................................................101 Disassembly Of The Differential And Speed Reducer...............................................................................102 Cleaning........................................................................................................................103 Inspection......................................................................................................................103 ASSEMBLY OF THE DRIVE UNIT..........................................................................................................103 Find The Correct Shim Set For The Hypoid Gear...................................................................................103 Assembly And Installation Of Pinion.............................................................................................104 Assembly Of The Differential And Ring Gear......................................................................................105 Input Gear For The Speed Reducer, Assembly......................................................................................109 Drive Axle And Hub Assembly, Assembly...........................................................................................109 INSTALLATION OF DRIVE UNIT..........................................................................................................110 Drive Unit, Installation........................................................................................................110 Traction Motor, Installation....................................................................................................111 TORQUE SPECIFICATIONS...................................................................................................................112 TROUBLESHOOTING.........................................................................................................................112 ELECTRICAL SYSTEM.......................................................................................................................113 GENERAL.............................................................................................................................113 "LX" SERIES DISPLAY PANEL...........................................................................................................114 Hourmeter Functions.............................................................................................................115 Battery Indicator Function......................................................................................................115 Status Code Function............................................................................................................116 "ZX" SERIES DISPLAY PANELS..........................................................................................................116 Display Panel...................................................................................................................116 Basic Display Panels............................................................................................................116 Performance Display.............................................................................................................118 Brush Wear Indicators...........................................................................................................121 SEM DISPLAY PANELS - FEATURES.......................................................................................................121 Description Of Common Features..................................................................................................122 LED SYMBOL INDICATORS...........................................................................................................122 LCD SCREEN......................................................................................................................122 BATTERY DISCHARGE INDICATOR (BDI)...............................................................................................122 SERVICE REMINDER................................................................................................................122 STATUS CODES....................................................................................................................122 HOURMETER.......................................................................................................................122 Additional Features Of Premium Display Panel ...................................................................................122 Descriptions Of Additional Features (Available With The Premium Display) .......................................................123 LCD SCREEN......................................................................................................................123 OPERATOR PASSWORDS..............................................................................................................123 DAILY CHECK LIST AND SERVICE ITEMS..............................................................................................123 PERFORMANCE MODELS..............................................................................................................123 STATUS CODE LISTS...............................................................................................................123 ADJUSTMENTS OF BDI..............................................................................................................124 SEM DISPLAY PANEL INDICATORS........................................................................................................124 All Indicator Symbols...........................................................................................................124 Hourmeter Indicator Symbol......................................................................................................125 Wrench Indicator Symbol.........................................................................................................125 Battery Indicator Symbol........................................................................................................125 Battery State-Of-Charge (BDI)...................................................................................................125 Brake Fluid Too Low Symbol......................................................................................................125 Parking Brake Symbol............................................................................................................125 Fasten Seat Belt Symbol.........................................................................................................125 LCD "Screen" (Standard Display Panel)...........................................................................................125 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM.............................................................................125 Alpha Numeric "Screen"..........................................................................................................125 "Star" Push Button..............................................................................................................126 Push Buttons #1 Through #5......................................................................................................126 OTHER CONTROL COMPONENTS............................................................................................................126 REPLACEMENT.............................................................................................................................127 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"............................................................................................127 Replace The Display Panel Assembly..............................................................................................127 Replace The Key Switch..........................................................................................................128 Indicator LEDs..................................................................................................................128 Battery Indicators..............................................................................................................128 Digital Display (Performance Display Panel Only) ...............................................................................128 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only)....................................130 Replace Parts Of The Basic Display Panel .......................................................................................130 Replace Parts Of The Performance Display Panel..................................................................................131 SEM DISPLAY PANEL...................................................................................................................132 Removal And Replacement.........................................................................................................132 REPLACE MOTOR CONTROLLER (SR or SP).................................................................................................132 OTHER CONTROL COMPONENTS............................................................................................................132 Start Swtich....................................................................................................................132 Brake Light Switch..............................................................................................................133 Seat Switch.....................................................................................................................134 Adjust The External Seat Switch.................................................................................................135 Switch For Optional Seat Brake..................................................................................................135 Parking Brake Switch............................................................................................................135 Direction Switches (Monotrol Pedal)............................................................................................136 Direction Control Switches (Steering Column)....................................................................................137 Direction Control Switches, E70-120XL3 (Steering Column)........................................................................138 Brake Fluid Switch..............................................................................................................138 Brush Wear And Over Temperature Sensors.........................................................................................138 Rocker Switches For Lights .....................................................................................................139 Accelerator Position Sensor.....................................................................................................139 On-Demand Steering Components...................................................................................................141 Lights, Converter, Relay And Reverse Alarm......................................................................................143 Horn And Horn Buttons...........................................................................................................146 Hydraulic Pump Switches.........................................................................................................147 CHECKS AND ADJUSTMENTS..................................................................................................................147 GENERAL.............................................................................................................................147 CONTROL AND POWER FUSES - "LX" OR "ZX"..............................................................................................147 CONTROL AND POWER FUSES - SEM.......................................................................................................150 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"........................................................................153 THERMAL SENSORS - SEM...............................................................................................................153 ADJUST THE START SWITCH.............................................................................................................153 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3...............................................................154 Direction Switches (MONOTROL)...................................................................................................156 ADJUST THE BRAKE LIGHT SWITCH...................................................................................................156 CHECK SEAT SWITCH...............................................................................................................156 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE.......................................................................................156 ADJUST THE PARKING BRAKE SWITCH.................................................................................................157 DIRECTIONAL SWITCHES............................................................................................................157 DIRECTIONAL SWITCHES (STEERING COLUMN)..........................................................................................157 HYDRAULIC PUMP SWITCHES.........................................................................................................157 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT..................................................................................157 ADJUST THE ACCELERATOR POSITION SENSOR..........................................................................................158 INTRODUCTION............................................................................................................................160 GENERAL.............................................................................................................................160 DESCRIPTION.........................................................................................................................160 Main Frame......................................................................................................................160 Other Frame Weldments...........................................................................................................162 Battery Restraint And Hood Frame................................................................................................163 Overhead Guard..................................................................................................................165 REPAIRS.................................................................................................................................165 OVERHEAD GUARD......................................................................................................................165 Removal.........................................................................................................................165 Installation....................................................................................................................165 BATTERY RESTRAINT AND SEAT ASSEMBLY.................................................................................................165 COUNTERWEIGHT.......................................................................................................................166 Removal.........................................................................................................................166 Installation....................................................................................................................167 TRACTION MOTOR......................................................................................................................168 Removing Traction Motor.........................................................................................................168 Installing Traction Motor.......................................................................................................169 HYRAULIC TANK.......................................................................................................................170 Inspection......................................................................................................................170 Repairs, Small Leaks............................................................................................................170 Repairs, Large Leaks............................................................................................................170 Cleaning........................................................................................................................171 Steam Method of Cleaning........................................................................................................171 Chemical Solution Method Of Cleaning............................................................................................171 Additional Preparations For Repair..............................................................................................171 PAINTING INSTRUCITONS...............................................................................................................172 LABEL REPLACEMENT...................................................................................................................174 INTRODUCTION............................................................................................................................175 GENERAL.............................................................................................................................175 DESCRIPTION AND OPERATION...........................................................................................................175 Carriages.......................................................................................................................175 Mast Mounts.....................................................................................................................176 TWO-STAGE MAST, LIMITED FREE-LIFT...................................................................................................177 Description and Operation.......................................................................................................177 TWO-STAGE MAST, FULL FREE-LIFT......................................................................................................179 Description.....................................................................................................................179 Operation.......................................................................................................................179 THREE-STAGE, FULL FREE-LIFT MAST....................................................................................................181 Description.....................................................................................................................181 Operation.......................................................................................................................181 INTRODUCTION ...........................................................................................................................183 GENERAL ............................................................................................................................183 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ...........................................................................................183 REPAIRS ................................................................................................................................184 FORKS ..............................................................................................................................184 Removal ........................................................................................................................184 Installation ...................................................................................................................185 CARRIAGES ..........................................................................................................................185 Removal, Standard Carriage .....................................................................................................185 Removal, Side–Shift Carriage ...................................................................................................186 Repairs ........................................................................................................................186 Installation, Standard Carriage ................................................................................................186 Installation, Side–Shift Carriage ..............................................................................................187 MAST ...............................................................................................................................188 Removal ........................................................................................................................188 Disassembly, Three–Stage FFL Mast ..............................................................................................194 Disassembly, Two–Stage LFL And Two–Stage FFL Masts .............................................................................188 Cleaning and Inspection ........................................................................................................194 Assembly, Two–Stage LFL And Two–Stage FFL Mast .................................................................................197 Assembly, Three–Stage FFL Mast .................................................................................................198 Installation, Mast .............................................................................................................199 LIFT CYLINDERS .....................................................................................................................200 Removal, Main Lift Cylinders ...................................................................................................200 Removal, Free–Lift Cylinder ....................................................................................................200 Disassembly, Lift Cylinders ....................................................................................................200 Assembly, Lift Cylinders .......................................................................................................201 Installation, Main Lift Cylinders ..............................................................................................202 Installation, Free–Lift Cylinder ...............................................................................................203 HEADER HOSE ARRANGEMENTS H/S/E/J2.00–3.20XM (H/S/E/J40–65XM) S/E/J2.00–3.00XL (S/E/J40–60XL) .......................................204 New Hose Installation, Two–Stage, LFL Mast .....................................................................................204 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .....................................................................204 New Hose Installation, Two–Stage FFL Mast ......................................................................................208 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .....................................................................208 New Hose Installation, Three–Stage FFL Mast ....................................................................................212 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ..................................................................217 HEADER HOSE ARRANGEMENTS H/E1.50–1.75XM, H/S2.00XMS (H/S/E25–35XM, H/S/E40XMS) and J1.60–2.00XMT (J30–40XMT) .......................219 New Hose Installation, Two–Stage LFL Mast ......................................................................................220 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .....................................................................220 New Hose Installation, Two–Stage FFL Mast ......................................................................................223 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .....................................................................223 New Hose Installation, Three–Stage, FFL Mast ...................................................................................227 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ..................................................................232 CHECKS AND ADJUSTMENTS .................................................................................................................233 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM .......................................................................................233 Check The Lift Cylinders For Leaks ............................................................................................233 Check The Tilt Cylinders For Leaks ............................................................................................233 ADJUST THE TILT CYLINDERS .........................................................................................................233 ADJUST THE LIFT CHAINS ............................................................................................................234 ADJUST THE MAST ...................................................................................................................235 ADJUST THE CARRIAGE ...............................................................................................................236 TROUBLESHOOTING.........................................................................................................................237 INTRODUCTION............................................................................................................................238 GENERAL.............................................................................................................................238 DESCRIPTION.........................................................................................................................239 Hydraulic System................................................................................................................239 OPERATION...........................................................................................................................239 Hydraulic System................................................................................................................239 Hydraulic Gear Pump.............................................................................................................240 Rotator Actuator Valve..........................................................................................................240 Steering Pump...................................................................................................................243 REPAIRS.................................................................................................................................247 HYDRAULIC TANK......................................................................................................................247 E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal.................................................................................247 J2.00-3.20XM (J40-65XM) Tank Removal............................................................................................247 Tank Inspection.................................................................................................................247 Tank Repairs, Small Leaks.......................................................................................................248 Tank Repairs, Large Leaks ......................................................................................................248 Tank Cleaning...................................................................................................................248 Steam Method Of Cleaning Tank...................................................................................................248 Chemical Solution Method Of Cleaning Tank.......................................................................................248 Additional Preparations For Tank repair.........................................................................................249 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation............................................................................249 J2.00-3.20XM (J40-65XM) Tank Installation.......................................................................................249 FILTER REPLACEMENT..................................................................................................................250 HYDRAULIC PUMP......................................................................................................................250 Removing E1.50-3.20XM (E25-65XM) and N30XMH Hydraulic Pump......................................................................250 Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump...............................................................................251 Pump Seal Replacement And Pump Assembly.........................................................................................251 Assemble Pump On The Motor......................................................................................................253 Install The Hydraulic Pump And Motor Assembly [E1.50-3.20XM (E25-65XM) and N30XMH]..............................................254 Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly...............................................................254 MAIN CONTROL VALVE..................................................................................................................255 STEERING PUMP.......................................................................................................................255 Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N30XMH................................................................255 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM)...........................................................................256 Pump Assembly And Installation..................................................................................................257 ROTARY ACTUATOR VALVE...............................................................................................................258 Disassembly, Cleaning and Inspection............................................................................................258 Assembly........................................................................................................................258 STEERING CONTROL UNIT...............................................................................................................258 Control Unit Removal............................................................................................................259 Control Unit Installation.......................................................................................................259 STEERING CYLINDER...................................................................................................................259 CHECKS AND ADJUSTMENTS..................................................................................................................261 MAIN CONTROL VALVE..................................................................................................................261 STEERING RELIEF VALVE...............................................................................................................261 TROUBLESHOOTING CHART...................................................................................................................261 SPECIFICATIONS..........................................................................................................................265 INTRODUCTION............................................................................................................................268 GENERAL.............................................................................................................................268 LEAD-ACID BATTERIES.................................................................................................................268 SPECIFIC GRAVITY....................................................................................................................269 CHEMICAL REACTION IN A CELL.........................................................................................................269 ELECTRICAL TERMS....................................................................................................................270 HOW TO SELECT THE BATTERY...........................................................................................................270 VOLTAGE OF A BATTERY................................................................................................................270 THE BATTERY AS A COUNTERWEIGHT......................................................................................................271 BATTERY RATINGS.....................................................................................................................271 Kilowatt-Hours..................................................................................................................272 BATTERY MAINTENANCE.....................................................................................................................272 SAFETY PROCEDURES...................................................................................................................272 MAINTENCE RECORDS...................................................................................................................273 THE NEW BATTERY.....................................................................................................................273 HOW TO CLEAN THE BATTERY............................................................................................................274 HOW TO ADD WATER....................................................................................................................274 THE HYDROMETER......................................................................................................................275 BATTERY TEMPERATURE.................................................................................................................275 CHARGING THE BATTERY................................................................................................................276 Types Of Battery Charges........................................................................................................277 Methods Of Charging.............................................................................................................278 Troubleshooting The Charger.....................................................................................................278 How to Know When The Battery Is Fully Charged...................................................................................279 WHERE TO CHARGE THE BATTERIES.......................................................................................................279 Equipment Needed................................................................................................................279 BATTERY CONNECTORS..................................................................................................................280 BATTERY CARE........................................................................................................................280 INTRODUCTION............................................................................................................................282 GENERAL.............................................................................................................................282 DESCRIPTION.........................................................................................................................282 REPAIRS.................................................................................................................................286 REMOVAL AND DISASSEMBLY.............................................................................................................286 ASSEMBLY AND INSTALLATION...........................................................................................................286 INTRODUCTION............................................................................................................................289 GENERAL.............................................................................................................................289 DESCRIPTION.........................................................................................................................289 OPERATION...........................................................................................................................290 E1.50-3.20XM (E25-65XM).........................................................................................................291 J2.00-3.20XM (J40-65XM).........................................................................................................291 Lift Section....................................................................................................................291 Tilt Section....................................................................................................................292 Relief Valve....................................................................................................................294 REPAIRS.................................................................................................................................295 MAIN CONTROL VALVE..................................................................................................................295 Removal.........................................................................................................................295 Disassembly.....................................................................................................................295 Cleaning And Inspection.........................................................................................................295 Assembly........................................................................................................................295 Installation, E1.50-3.20XM (E25-65XM)...........................................................................................297 Installation, J2.00-3.20XM (J40-65XM)...........................................................................................299 CONTROL LEVER LINKAGE, E1.50-3.20XM (E25-65XM)......................................................................................300 Removal.........................................................................................................................300 Disassembly.....................................................................................................................301 Assembly And Installation.......................................................................................................301 CONTROL VALVE LINKAGE, E1.50-3.20XM (E25-65XM)......................................................................................301 Removal And Disassembly.........................................................................................................301 Assembly And Installation.......................................................................................................302 CONTROL LEVER LINKAGE, J2.00-3.20XM (J40-65XM)......................................................................................302 Removal.........................................................................................................................302 Disassembly.....................................................................................................................302 Assembly And Installation.......................................................................................................304 CHECKS AND ADJUSTMENTS..................................................................................................................305 PRESSURE RELIEF VALVES..............................................................................................................305 Primary Relief Valve............................................................................................................305 Secondary Relief Valve..........................................................................................................305 TROUBLESHOOTING.........................................................................................................................306 INTRODUCTION............................................................................................................................308 GENERAL.............................................................................................................................308 SERIAL NUMBER DATA..................................................................................................................308 HOW TO MOVE A DISABLED LIFT TRUCK...................................................................................................308 How To Tow A Lift Truck ........................................................................................................308 HOW TO PUT A LIFT TRUCK ON BLOCKS...................................................................................................309 How To Raise The Drive Tires....................................................................................................309 How To Raise The Steering Tires.................................................................................................309 MAINTENANCE SCHEDULE....................................................................................................................310 MAINTENANCE PROCEDURES..................................................................................................................313 EVERY 8 HOURS OR DAILY..................................................................................................................313 Tires And Wheels....................................................................................................................313 Forks...............................................................................................................................314 Fork Adjustment.....................................................................................................................314 Fork Removal........................................................................................................................314 Fork Installation...................................................................................................................315 Inspection Of Forks, Mast And Lift Chains...........................................................................................315 Safety Labels.......................................................................................................................316 Steering Column Latch...............................................................................................................316 Operator Restraint System...........................................................................................................317 Battery Restraint System, E25-65XM, E25-65XM2......................................................................................317 Battery Restraint System - J40-65XM-65XM, J40-65XM2................................................................................318 Battery.............................................................................................................................318 Hydraulic System....................................................................................................................319 HOW TO MAKE CHECKS WITH THE KEY "ON"................................................................................................320 Gauges, Horn And Fuses..........................................................................................................320 Steering System.................................................................................................................320 Service Brake...................................................................................................................320 Parking Brake...................................................................................................................321 Control Levers And Pedals.......................................................................................................321 Lift System Operation...........................................................................................................321 EVERY 350 HOURS OR THREE MONTHS ........................................................................................................322 HYDRAULIC TANK BREATHER.............................................................................................................322 DIFFERENTIAL AND SPEED REDUCER......................................................................................................322 WHEEL NUT TORQUES...................................................................................................................323 STEERING AXLE SPINDLES..............................................................................................................323 MAST................................................................................................................................323 LIFT CHAINS.........................................................................................................................324 Check For Wear..................................................................................................................324 Lubrication.....................................................................................................................324 FORKS...............................................................................................................................324 BRAKE FLUID.........................................................................................................................325 OTHER LUBRICATION...................................................................................................................325 SEAT BRAKE (E25-65XM, E25-65XM2 Only................................................................................................325 ELECTRICAL INSPECTION...............................................................................................................325 Contactors......................................................................................................................326 Motor Brushes...................................................................................................................326 Motor Brushes, General..........................................................................................................326 EVERY 2000 HOURS OR YEARLY..............................................................................................................336 HYDRAULIC SYSTEM....................................................................................................................336 Change The Filter For The Hydraulic Oil.........................................................................................336 Change The Hydraulic Oil........................................................................................................337 DIFFERENTIAL AND SPEED REDUCER......................................................................................................337 SERVICE BRAKES......................................................................................................................337 CONTACTORS..........................................................................................................................338 WHEEL BEARINGS......................................................................................................................338 Steer Wheels, Lubrication.......................................................................................................338 Drive Wheels, Lubrication.......................................................................................................338 LIFT CHAINS.........................................................................................................................338 GENERAL PROCEDURE.......................................................................................................................338 HOW TO CHARGE THE BATTERY...........................................................................................................338 HOW TO CHANGE THE BATTERY...........................................................................................................340 General.........................................................................................................................340 Change The E25-65XM, E25-65XM2 Battery..........................................................................................340 Change The J40-65XM, J40-65XM2 Battery..........................................................................................342 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.........................................................................................344 Check The Lift Cylinders For Leaks..............................................................................................344 Check The Tilt Cylinders For Leaks..............................................................................................344 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)...............................................................................345 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)...............................................................................346 LIFT CHAIN ADJUSTMENTS..............................................................................................................346 HOW TO CHECK THE PMT CIRCUIT........................................................................................................347 WELDING REPAIRS.....................................................................................................................348 CHANGES TO THE OVERHEAD GUARD.......................................................................................................348 TIRES AND WHEELS, E25-65XM, E25-65XM2...............................................................................................348 Remove The Wheels From The Lift Truck..........................................................................................349 Remove And Install The Tire On The Wheel........................................................................................349 PNEUMATIC TIRES AND WHEELS J40-65XM, J40-65XM2......................................................................................349 Remove The Wheels From The Lift Truck...........................................................................................349 Remove The Wheel From The Pneumatic Tire........................................................................................350 Install The Wheel In The Pneumatic Tire.........................................................................................351 Add Air To The Tires............................................................................................................352 Install The Wheels..............................................................................................................352 SOLID RUBBER TIRES ON PNEUMATIC WHEELS..............................................................................................352 Remove The Wheels From The Lift Truck...........................................................................................352 Remove The Solid Rubber Tire From The Pneumatic Wheel...........................................................................352 Install The Solid Rubber Tire On The Pneumatic Wheel............................................................................354 Install The Wheels .............................................................................................................354 REFERENCE TABLE.........................................................................................................................355 Adhesive And Sealants ..............................................................................................................355 INTRODUCTION............................................................................................................................356 NOMENCLATURE, THREADS...............................................................................................................356 STRENGTH IDENTIFICATION.............................................................................................................357 TABLE 1. BOLTS AND SCREWS...............................................................................................................357 TABLE 2. STUDS AND NUTS.................................................................................................................358 TABLE 3. TORQUE NUTS....................................................................................................................359 TABLE 4. TORQUE NUTS WITH NYLON INSERT..................................................................................................360 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...............................................................................................361 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.............................................................................................362 SEM DISPLAY PANEL.......................................................................................................................365 GENERAL.............................................................................................................................365 SEM DISPLAY PANEL FEATURES..........................................................................................................365 Description Of Common Features..................................................................................................365 LED SYMBOL INDICATORS...........................................................................................................365 LED SCREEN .....................................................................................................................365 BATTERY DISCHARGE INDICATOR (BDI)...............................................................................................365 SERVCE REMINDER.................................................................................................................366 STATUS CODES....................................................................................................................366 HOURMETER.......................................................................................................................366 Additional Features Of Premium Display Panel....................................................................................366 Descriptions Of Additional Features (Available With The Premium Display)........................................................366 LCD SCREEN......................................................................................................................366 OPERATOR PASSWORDS..............................................................................................................366 DAILY CHECK LIST AND SERVICE ITEMS..............................................................................................367 PERFORMANCE MODES...............................................................................................................367 STATUS CODES LIST...............................................................................................................367 ADJUSTMENT OF BDI...............................................................................................................368 SEM DISPLAY PANEL INDICATORS........................................................................................................368 All Indicator Symbols...........................................................................................................368 Hourmeter Indicator Symbol......................................................................................................369 Wrench Indicator Symbol.........................................................................................................369 Battery Indicator Symbol........................................................................................................369 Battery State-Of-Charge (BDI)...................................................................................................369 Brake Fluid Too Low Symbol......................................................................................................369 Parking Brake Symbol............................................................................................................369 Fasten Seat Belt Symbol.........................................................................................................369 LCD Screen (Standard Display Panel).............................................................................................369 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL..................................................................................369 Alpha Numeric Screen............................................................................................................369 "STAR" Push Button..............................................................................................................370 Push Buttons #1 Through #5......................................................................................................370 ADJUSTMENTS WITH A COMPUTER.........................................................................................................371 COMPUTER SYSTEM.................................................................................................................371 Connect A PC To The SEM Display Panel...........................................................................................371 ITW SWITCHES SOFTWARE PROGRAM (For SEM Display Panel)...........................................................................372 Description.................................................................................................................372 Where To Get Help...........................................................................................................372 Hardware And Software Requirements..........................................................................................372 How To Start The ITW SWITCHES Program.......................................................................................373 Menus.......................................................................................................................373 Create A Setup File.........................................................................................................381 REPLACEMENT.........................................................................................................................401 GENERAL.........................................................................................................................401 SEM DISPLAY PANEL...............................................................................................................401 Removal And Replacement ........................................................................................................401 TRANSISTOR MOTOR CONTROLLERS (SR AND SP) DESCRIPTION, CHECKS & ADJUSTMENTS, TROUBLESHOOTING, REPAIRS, AND THEORY OF OPERATION...........404 DESCRIPTION.........................................................................................................................404 General.........................................................................................................................404 Model Number Data For Transistor Motor Controllers (SR and SP)..................................................................405 MOTOR CONTROLLER, CHECKS AND ADJUSTMENTS............................................................................................407 CHECKS AND ADJUSTMENTS USING A HAND SET.............................................................................................408 General.........................................................................................................................408 Connect Hand Set................................................................................................................409 Start Sequence..................................................................................................................409 Check Or Delete Stored Status Codes.............................................................................................409 Returning The Lift Truck To Normal Operation....................................................................................410 Checks And Adustments On The Work Bench.........................................................................................410 How To Check And Adjust The Registers...........................................................................................412 ADJUSTMENTS - FUNCTION PARAMETERS...................................................................................................413 General.........................................................................................................................413 Function Numbers................................................................................................................413 When The Hand Set Is Connected To A Motor Controller In The Lift Truck..........................................................414 FUNCTION NUMBER DESCRIPTIONS........................................................................................................415 TRACTION MOTOR CONTROLLER (LABEL LETTER - SR).......................................................................................415 FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY...........................................................................................420 PUMP MOTOR CONTROLLER (LABEL LETTER - SP)...........................................................................................422 FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY...........................................................................................425 TROUBLESHOOTING - STATUS CODE CHARTS....................................................................................................430 TROUBLESHOOTING.....................................................................................................................431 General.........................................................................................................................431 Status Codes....................................................................................................................431 REPAIRS.................................................................................................................................459 GENERAL.............................................................................................................................459 GENERAL MAINTENANCE INSTRUCTIONS....................................................................................................459 Special Precautions.............................................................................................................459 FUSES...............................................................................................................................462 CONTACTORS..........................................................................................................................462 Contactor Repair................................................................................................................462 CONTACTOR DRIVER MODULE.............................................................................................................464 Replace Contactor Driver........................................................................................................464 MOTOR CONTROLLER PLUG...............................................................................................................464 BRUSH WEAR INDICATORS...............................................................................................................464 THERMAL SENSORS.....................................................................................................................465 REPLACE MOTOR CONTROLLER............................................................................................................465 THEORY OF OPERATION.....................................................................................................................470 GENERAL.............................................................................................................................470 DESCRIPTION OF SEM SYSTEM...........................................................................................................470 OPERATION OF SEM SYSTEM (SR MOTOR CONTROLLER).......................................................................................471 Reverse Circuit.................................................................................................................471 Performance and Efficiency......................................................................................................471 Field Weakening.................................................................................................................472 Regenerative Braking............................................................................................................472 INTRODUCTION........................................................................................................................472 General.........................................................................................................................472 Creep Speed.....................................................................................................................472 Controlled Acceleration.........................................................................................................472 Current Limit...................................................................................................................473 BRAKING.............................................................................................................................473 Regenerative Braking to Zero Speed..............................................................................................473 Pedal Position Braking..........................................................................................................473 Auto Braking....................................................................................................................473 AUXILIARY SPEED CONTROL.............................................................................................................473 Field Weakening.................................................................................................................473 Speed Limits....................................................................................................................474 RAMP OPERATION......................................................................................................................474 Ramp Start......................................................................................................................474 Anti-Rollback...................................................................................................................474 STEER PUMP CONTACTOR TIME DELAY.....................................................................................................474 COIL DRIVERS AND INTERNAL COIL SUPPRESSION..........................................................................................474 SYSTEM PROTECTIVE OVERRIDE..........................................................................................................474 SRO (Static Return to Off)......................................................................................................474 Accelerator Volts Hold Off......................................................................................................474 Pulse Monitor Trip (PMT)........................................................................................................474 Thermal Protector (TP)..........................................................................................................475 Low Voltage.....................................................................................................................475 SP PUMP MOTOR CONTROLLERS...........................................................................................................475 CONTACTOR DRIVER MODULE.............................................................................................................475 DIAGNOSTICS.........................................................................................................................476 System Diagnostics..............................................................................................................476 Standard Status Codes...........................................................................................................476 Stored Status Codes.............................................................................................................476 Hourmeter Readings..............................................................................................................476 Maintenance Management Capability...............................................................................................476 SR (SEM) AND SP TRANSISTOR MOTOR CONTROLLER,Parameter Tables............................................................................482 GENERAL.............................................................................................................................482 Function Numbers...............................................................................................................482 MOTOR CONTROLLER CHECKS AND ADJUSTMENTS.............................................................................................483 TABLE 1.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V) (Standard Speed Motor With EE ....484 Parameter Tables................................................................................................................483 TABLE 2.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V) (High Speed Motor With E or ES....486 TABLE 3.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V).............................................488 TABLE 4.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E45-65XM2 (F108) (36 to 48V) (9 Inch Traction Motor)...........490 TABLE 5.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E45-65XM2 (F108) (36 to 48V) (11 Inch Traction Motor)..........493 TABLE 6.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER -E45-65XM2 (F108) (36 to 48V)..............................................496 TABLE 7.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER -J45-65XM2 (A216) (36 to 48V) (E OR ES RATED)....................498 TABLE 8.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER -J45-65XM2 (A216) (36 to 48V) (EE RATED).........................500 TABLE 9.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - J45-65XM2 (A216) (36 to 48V).............................................502 TABLE 10.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V) (9 INCH MOTOR).....................504 TABLE 11.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V) (11 INCH MOTOR)....................507 TABLE 12.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V)..............................................510 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers................................512 COMPUTER SYSTEM.....................................................................................................................512 Connect A PC To A Control Card..................................................................................................513 HYTECt SOFTWARE PROGRAM ............................................................................................................514 How To Start The Program........................................................................................................514 Selecting The Communications Port...............................................................................................515 Verification Of Controller and Lift Truck.......................................................................................515 Select The Lift Truck Series....................................................................................................516 Undefined Controller Card.......................................................................................................517 Controller Card Register Parameter List.........................................................................................517 How To Enter A New Parameter....................................................................................................518 How To Save A Changed Parameter File............................................................................................519 How To Load A Saved Parameter File..............................................................................................519 How To Return To Factory Default Settings.......................................................................................520 How To Save Changes To The Controller Card......................................................................................521 How To View The Status Codes ...................................................................................................521 Saving The Status Code To Disk..................................................................................................522 Closing and Clearing The Status Code List.......................................................................................523 COMMUNICATIONS PROGRAM (MODEM)......................................................................................................523 Requirements....................................................................................................................524 README File.....................................................................................................................525 GE Sentry Software..................................................................................................................525 Getting Started.................................................................................................................525 Where To Get Help...............................................................................................................526 Hardware and Software Requirements..............................................................................................526 Installation of the GE SENTRY SOFTWARE..........................................................................................526 How To Start The GE SENTRY Program..............................................................................................526 How To Reset The MIN and MAX Display............................................................................................528 How To Exit The GE SENTRY Program...............................................................................................528 INTRODUCTION............................................................................................................................529 GENERAL.............................................................................................................................529 DESCRIPTION.........................................................................................................................529 REPAIRS.................................................................................................................................530 STEERING AXLE ASSEMBLY..............................................................................................................530 Removal.........................................................................................................................530 Installation....................................................................................................................531 WHEELS AND HUBS.....................................................................................................................531 Removal and Disassembly.........................................................................................................531 Cleaning........................................................................................................................533 Assembly And Installation.......................................................................................................533 SPINDLES, BEARINGS AND LINKS........................................................................................................533 Removal And Disassembly.........................................................................................................533 Cleaning and Inspection.........................................................................................................534 Assembly and Installation.......................................................................................................534 TORQUE SPECIFICATIONS...................................................................................................................535 TROUBLESHOOTING.........................................................................................................................536 INTRODUCTION............................................................................................................................537 GENERAL.............................................................................................................................537 DESCRIPTION.........................................................................................................................537 OPERATION...........................................................................................................................537 REPAIRS.................................................................................................................................538 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................................................538 Removal of the Assembly Components..............................................................................................542 Disassembly of the Steering Control Unit........................................................................................543 Cleaning of the Steering Control Unit...........................................................................................543 Assembly of the Steering Control Unit...........................................................................................543 Installation of the Steering Control Unit.......................................................................................543 Installation of the Assembly Components.........................................................................................543 CHECKS AND ADJUSTMENTS..................................................................................................................551 REMOVE AIR FROM THE SYSTEM..........................................................................................................551 TROUBLESHOOTING.........................................................................................................................551 STEERING SYSTEM.........................................................................................................................553 GENERAL.............................................................................................................................553 DESCRIPTION.........................................................................................................................555 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................................................556 Removal Of The Assembly Components..............................................................................................556 Installation Of The Assembly Components.........................................................................................560 POWER STEERING MOTOR AND PUMP...........................................................................................................561 DESCRIPTION.........................................................................................................................561 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)..................................561 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3).......................................................................561 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)....................................................................................562 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)...................................................................................564 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)..................................................................................565 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]......................................565 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)..................................................................................566 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)................................................................................568 REPAIRS, POWER STEERING PUMP........................................................................................................569 Seal Replacement................................................................................................................570 HYDRAULIC STEERING MOTOR................................................................................................................570 DESCRIPTION.........................................................................................................................570 REPAIRS, HYDRAULIC STEERING MOTOR...................................................................................................571 Removal ........................................................................................................................571 Disassembly.....................................................................................................................571 Cleaning And Inspection.........................................................................................................571 Assembly........................................................................................................................572 Installation, Hydraulic Steering Motor..........................................................................................573 CHECKS AND ADJUSTMENTS..................................................................................................................573 AIR IN THE STEERING SYSTEM..........................................................................................................573 CHECK STEERING PRESSURE.............................................................................................................573 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only).......................................................................574 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS.......................................................................................575 TROUBLESHOOTING.........................................................................................................................577 INTRODUCTION............................................................................................................................580 GENERAL.............................................................................................................................580 DESCRIPTION.........................................................................................................................580 REPAIRS.................................................................................................................................580 REMOVAL.............................................................................................................................580 DISASSEMBLY.........................................................................................................................580 CLEANING............................................................................................................................580 ASSEMBLY............................................................................................................................580 Tilt Cylinders with O-Rings or Single Lip Seals.................................................................................580 Tilt Cylinders for the XM and XMS Models........................................................................................581 Tilt Cylinders for H700 800A and Early Model H700 920B..........................................................................583 INSTALLATION........................................................................................................................583 Tilt Cylinders Using Chevron Packing............................................................................................584 CHECKS AND ADJUSTMENTS..................................................................................................................586 CHECK THE TILT CYLINDERS FOR LEAKS..................................................................................................586 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.............................................................................586 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS................................................................................587 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS...............................................................................588 TROUBLESHOOTING.........................................................................................................................590
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
2 reviews for Hyster E25 35XM₂, E40XMS₂ service manual – PDF DOWNLOAD
Add a review
Watson Mccoy –
Very efficient
Ephraim Isaiah –
satisfactory transaction