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Hyster E25 35XM, E40XMS service manual – PDF DOWNLOAD
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Hyster E25 35XM, E40XMS service manual
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Description
Hyster E25 35XM, E40XMS service manual
File Details:
Hyster E25 35XM, E40XMS service manual
Language : English
Pages : 548
Size : 16.28 MB
Downloadable : Yes
Format : PDF
HYSTER E25 35XM, E40XMS SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster E25 35XM, E40XMS 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 35XM, E40XMS 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 INTRODUCTION............................................................................................................... 85 GENERAL................................................................................................................ 85 DESCRIPTION............................................................................................................ 85 REPAIRS.................................................................................................................... 85 DRIVE UNIT ASSEMBLY.................................................................................................... 85 Remove The Complete Drive Unit Assembly As A Unit.................................................................. 85 Traction Motor, Removal............................................................................................ 86 Drive Unit And Speed Reducer, Removal.............................................................................. 87 Disassembly Of The Drive Axle...................................................................................... 88 Disassembly Of The Differential And Speed Reducer.................................................................. 89 Cleaning........................................................................................................... 90 Inspection......................................................................................................... 90 ASSEMBLY OF THE DRIVE UNIT............................................................................................. 90 Find The Correct Shim Set For The Hypoid Gear...................................................................... 90 Assembly And Installation Of Pinion................................................................................ 91 Assembly Of The Differential And Ring Gear......................................................................... 92 Input Gear For The Speed Reducer, Assembly......................................................................... 96 Drive Axle And Hub Assembly, Assembly.............................................................................. 96 INSTALLATION OF DRIVE UNIT............................................................................................. 97 Drive Unit, Installation........................................................................................... 97 Traction Motor, Installation....................................................................................... 98 TORQUE SPECIFICATIONS...................................................................................................... 99 TROUBLESHOOTING............................................................................................................ 99 ELECTRICAL SYSTEM..........................................................................................................100 GENERAL................................................................................................................100 "LX" SERIES DISPLAY PANEL..............................................................................................101 Hourmeter Functions................................................................................................102 Battery Indicator Function.........................................................................................102 Status Code Function...............................................................................................103 "ZX" SERIES DISPLAY PANELS.............................................................................................103 Display Panel......................................................................................................103 Basic Display Panels...............................................................................................103 Performance Display................................................................................................105 Brush Wear Indicators..............................................................................................108 SEM DISPLAY PANELS - FEATURES..........................................................................................108 Description Of Common Features.....................................................................................109 LED SYMBOL INDICATORS..............................................................................................109 LCD SCREEN.........................................................................................................109 BATTERY DISCHARGE INDICATOR (BDI)..................................................................................109 SERVICE REMINDER...................................................................................................109 STATUS CODES.......................................................................................................109 HOURMETER..........................................................................................................109 Additional Features Of Premium Display Panel ......................................................................109 Descriptions Of Additional Features (Available With The Premium Display) ..........................................110 LCD SCREEN.........................................................................................................110 OPERATOR PASSWORDS.................................................................................................110 DAILY CHECK LIST AND SERVICE ITEMS.................................................................................110 PERFORMANCE MODELS.................................................................................................110 STATUS CODE LISTS..................................................................................................110 ADJUSTMENTS OF BDI.................................................................................................111 SEM DISPLAY PANEL INDICATORS...........................................................................................111 All Indicator Symbols..............................................................................................111 Hourmeter Indicator Symbol.........................................................................................112 Wrench Indicator Symbol............................................................................................112 Battery Indicator Symbol...........................................................................................112 Battery State-Of-Charge (BDI)......................................................................................112 Brake Fluid Too Low Symbol.........................................................................................112 Parking Brake Symbol...............................................................................................112 Fasten Seat Belt Symbol............................................................................................112 LCD "Screen" (Standard Display Panel)..............................................................................112 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM................................................................112 Alpha Numeric "Screen".............................................................................................112 "Star" Push Button.................................................................................................113 Push Buttons #1 Through #5.........................................................................................113 OTHER CONTROL COMPONENTS...............................................................................................113 REPLACEMENT................................................................................................................114 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"...............................................................................114 Replace The Display Panel Assembly.................................................................................114 Replace The Key Switch.............................................................................................115 Indicator LEDs.....................................................................................................115 Battery Indicators.................................................................................................115 Digital Display (Performance Display Panel Only) ..................................................................115 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only).......................117 Replace Parts Of The Basic Display Panel ..........................................................................117 Replace Parts Of The Performance Display Panel.....................................................................118 SEM DISPLAY PANEL......................................................................................................119 Removal And Replacement............................................................................................119 REPLACE MOTOR CONTROLLER (SR or SP)....................................................................................119 OTHER CONTROL COMPONENTS...............................................................................................119 Start Swtich.......................................................................................................119 Brake Light Switch.................................................................................................120 Seat Switch........................................................................................................121 Adjust The External Seat Switch....................................................................................122 Switch For Optional Seat Brake.....................................................................................122 Parking Brake Switch...............................................................................................122 Direction Switches (Monotrol Pedal)...............................................................................123 Direction Control Switches (Steering Column).......................................................................124 Direction Control Switches, E70-120XL3 (Steering Column)...........................................................125 Brake Fluid Switch.................................................................................................125 Brush Wear And Over Temperature Sensors............................................................................125 Rocker Switches For Lights ........................................................................................126 Accelerator Position Sensor........................................................................................126 On-Demand Steering Components......................................................................................128 Lights, Converter, Relay And Reverse Alarm.........................................................................130 Horn And Horn Buttons..............................................................................................133 Hydraulic Pump Switches............................................................................................134 CHECKS AND ADJUSTMENTS.....................................................................................................134 GENERAL................................................................................................................134 CONTROL AND POWER FUSES - "LX" OR "ZX".................................................................................134 CONTROL AND POWER FUSES - SEM..........................................................................................137 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"...........................................................140 THERMAL SENSORS - SEM..................................................................................................140 ADJUST THE START SWITCH................................................................................................140 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3..................................................141 Direction Switches (MONOTROL)......................................................................................143 ADJUST THE BRAKE LIGHT SWITCH......................................................................................143 CHECK SEAT SWITCH..................................................................................................143 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE..........................................................................143 ADJUST THE PARKING BRAKE SWITCH....................................................................................144 DIRECTIONAL SWITCHES...............................................................................................144 DIRECTIONAL SWITCHES (STEERING COLUMN).............................................................................144 HYDRAULIC PUMP SWITCHES............................................................................................144 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT.....................................................................144 ADJUST THE ACCELERATOR POSITION SENSOR.............................................................................145 EV-100ZXE SCR MOTOR CONTROLLER, Description, Adjustments, Troubleshooting, Repairs, and Theory.............................147 GENERAL................................................................................................................147 Model Number Data For EV-100ZX Controller..........................................................................148 REGISTER PARAMETERS....................................................................................................157 General............................................................................................................157 Function Members...................................................................................................157 CONTROL CARD, CHECKS AND ADJUSTMENTS...................................................................................157 HAND SET...............................................................................................................158 How To Check And Adjust The Registers..............................................................................158 How To Scroll Through The Fault Codes And Clear Them...............................................................158 Checks And Adjustments On The Work Bench...........................................................................159 When The Hand Set Is Connected To A Control Card Installed In A Lift Truck.........................................160 FUNCTION NUMBER DESCRIPTIONS...........................................................................................161 TRACTION CONTROL CARDS (LABEL LETTERS - ZH AND ZY).....................................................................162 PUMP CONTROL CARD (LABEL LETTER ZP)....................................................................................168 REGISTER PARAMETERS....................................................................................................172 TROUBLESHOOTING........................................................................................................172 Status Codes.......................................................................................................173 REGISTER MAPS..........................................................................................................173 STATUS CODE CHARTS.........................................................................................................182 REPAIRS....................................................................................................................214 FUSES..................................................................................................................215 CHECK AN SCR...........................................................................................................215 THE SCR ASSEMBLY.......................................................................................................216 THERMAL PROTECTOR......................................................................................................216 REPLACE THE SCR 1 ASSEMBLY.............................................................................................216 THE "OFF" CIRCUIT FOR SCR 1............................................................................................216 Check The Reactor Assembly.........................................................................................216 Check Suppressors For SCR 2 And SCR 5..............................................................................217 Check SCR 2 And SCR 5..............................................................................................217 Replace SCR 2 And SCR 5............................................................................................217 Check Capacitor C1.................................................................................................217 DIODES D3 AND D4.......................................................................................................217 Check The Diodes D3 And D4.........................................................................................218 Replacement, Diodes D3 And D4......................................................................................218 MOTOR CURRENT SENSOR...................................................................................................218 CONTACTORS.............................................................................................................218 Contactor Repair...................................................................................................219 CONTROL CARD...........................................................................................................220 CONTROL CARD PLUGS.....................................................................................................221 Brush Wear Indicators..............................................................................................222 THEORY OF OPERATION........................................................................................................223 ELECTRONIC SPEED CONTROLS..............................................................................................223 The Silicon Controlled Rectifier (SCR).............................................................................223 A Motor Circuit That Operates With Pulses..........................................................................223 Traction Circuit...................................................................................................225 Hydraulic Pump Motor...............................................................................................225 The SCR 1 "OFF" Circuit............................................................................................226 INDUCTION CURRENT FROM THE MOTOR.......................................................................................228 CONTROL CARDS..........................................................................................................228 Pulse Monitor Trip (PMT) (Traction Circuit Only)...................................................................228 SRO Circuit (Traction Circuit Only)................................................................................229 SEQUENCE OF OPERATION..................................................................................................230 Control Card Adjustments (Traction Circuit)........................................................................230 Accelerator Control................................................................................................233 SCR CONTROL (HYDRAULIC PUMP MOTOR).....................................................................................233 CONTACTORS.............................................................................................................234 CIRCUIT PROTECTION.....................................................................................................235 Traction Circuit Fuse..............................................................................................235 Current Limit......................................................................................................235 Thermal Protection.................................................................................................235 Suppressors........................................................................................................235 TRUCK MANAGEMENT MODULE (TMM1).........................................................................................235 TABLE 8. Terminal And Plug Wire Connections For TMM1 Module........................................................236 DISPLAY PANELS.........................................................................................................236 Display Panel......................................................................................................236 Basic Display......................................................................................................236 Performance Display................................................................................................238 Brush Wear Indicators..............................................................................................241 EV-100ZX SCR MOTOR CONTROLLER, Parameter Tables............................................................................242 REGISTER PARAMETERS....................................................................................................242 General............................................................................................................242 Function Number....................................................................................................243 CONTROL CARD, CHECKS AND ADJUSTMENTS...................................................................................243 TABLE 1. EV-100ZX Parameters (Heavey Duty Motor (8702303) [Traction Card Type ZH or Zy With Regenerative Braking...........244 TABLE 2. EV-100ZX Parameters (Heavy Duty Motor (8702303) [Traction Card Type ZH or ZY No Regenerative Braking..............247 TABLE 3. EV-100ZX Parameters (Standard Motor (P/N 8702301 or 8702302) [Traction Card Type ZH or ZY With Regen. Braking ....250 TABLE 4. EV-100ZX Parameters (Standard Motor (P/N 8702301 or 8702302) [Traction Card Type ZH or ZY No Regen. Braking......253 TABLE 5. EV-100ZX Parameters-(Standard Motor (P/N 8702301 or 8702302) (Low Energy System)(Traction Card Type ZH and ZY.....256 TABLE 6. EV-100ZX Parameters (Standard System) (Hydraulic Pump Card Type ZP With or Without Lift Interrupt)................259 TABLE 7. EV-100ZX Parameters (Low Energy System) (Hydraulic Pump Card Type ZP With or Without Lift Interrupt).............259 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers...................265 COMPUTER SYSTEM........................................................................................................265 Connect A PC To A Control Card.....................................................................................266 HYTECt SOFTWARE PROGRAM ...............................................................................................267 How To Start The Program...........................................................................................267 Selecting The Communications Port..................................................................................268 Verification Of Controller and Lift Truck..........................................................................268 Select The Lift Truck Series.......................................................................................269 Undefined Controller Card..........................................................................................270 Controller Card Register Parameter List............................................................................270 How To Enter A New Parameter.......................................................................................271 How To Save A Changed Parameter File...............................................................................272 How To Load A Saved Parameter File.................................................................................272 How To Return To Factory Default Settings..........................................................................273 How To Save Changes To The Controller Card.........................................................................274 How To View The Status Codes ......................................................................................274 Saving The Status Code To Disk.....................................................................................275 Closing and Clearing The Status Code List..........................................................................276 COMMUNICATIONS PROGRAM (MODEM).........................................................................................276 Requirements.......................................................................................................277 README File........................................................................................................278 GE Sentry Software.....................................................................................................278 Getting Started....................................................................................................278 Where To Get Help..................................................................................................279 Hardware and Software Requirements.................................................................................279 Installation of the GE SENTRY SOFTWARE.............................................................................279 How To Start The GE SENTRY Program.................................................................................279 How To Reset The MIN and MAX Display...............................................................................281 How To Exit The GE SENTRY Program..................................................................................281 INTRODUCTION...............................................................................................................282 GENERAL................................................................................................................282 DESCRIPTION............................................................................................................282 Main Frame.........................................................................................................282 Other Frame Weldments..............................................................................................284 Battery Restraint And Hood Frame...................................................................................285 Overhead Guard.....................................................................................................287 REPAIRS....................................................................................................................287 OVERHEAD GUARD.........................................................................................................287 Removal............................................................................................................287 Installation.......................................................................................................287 BATTERY RESTRAINT AND SEAT ASSEMBLY....................................................................................287 COUNTERWEIGHT..........................................................................................................288 Removal............................................................................................................288 Installation.......................................................................................................289 TRACTION MOTOR.........................................................................................................290 Removing Traction Motor............................................................................................290 Installing Traction Motor..........................................................................................291 HYRAULIC TANK..........................................................................................................292 Inspection.........................................................................................................292 Repairs, Small Leaks...............................................................................................292 Repairs, Large Leaks...............................................................................................292 Cleaning...........................................................................................................293 Steam Method of Cleaning...........................................................................................293 Chemical Solution Method Of Cleaning...............................................................................293 Additional Preparations For Repair.................................................................................293 PAINTING INSTRUCITONS..................................................................................................294 LABEL REPLACEMENT......................................................................................................296 INTRODUCTION...............................................................................................................297 GENERAL................................................................................................................297 DESCRIPTION AND OPERATION..............................................................................................297 Carriages..........................................................................................................297 Mast Mounts........................................................................................................298 TWO-STAGE MAST, LIMITED FREE-LIFT......................................................................................299 Description and Operation..........................................................................................299 TWO-STAGE MAST, FULL FREE-LIFT.........................................................................................301 Description........................................................................................................301 Operation..........................................................................................................301 THREE-STAGE, FULL FREE-LIFT MAST.......................................................................................303 Description........................................................................................................303 Operation..........................................................................................................303 INTRODUCTION ..............................................................................................................305 GENERAL ...............................................................................................................305 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ..............................................................................305 REPAIRS ...................................................................................................................306 FORKS .................................................................................................................306 Removal ...........................................................................................................306 Installation ......................................................................................................307 CARRIAGES .............................................................................................................307 Removal, Standard Carriage ........................................................................................307 Removal, Side–Shift Carriage ......................................................................................308 Repairs ...........................................................................................................308 Installation, Standard Carriage ...................................................................................308 Installation, Side–Shift Carriage .................................................................................309 MAST ..................................................................................................................310 Removal ...........................................................................................................310 Disassembly, Three–Stage FFL Mast .................................................................................316 Disassembly, Two–Stage LFL And Two–Stage FFL Masts ................................................................310 Cleaning and Inspection ...........................................................................................316 Assembly, Two–Stage LFL And Two–Stage FFL Mast ....................................................................319 Assembly, Three–Stage FFL Mast ....................................................................................320 Installation, Mast ................................................................................................321 LIFT CYLINDERS ........................................................................................................322 Removal, Main Lift Cylinders ......................................................................................322 Removal, Free–Lift Cylinder .......................................................................................322 Disassembly, Lift Cylinders .......................................................................................322 Assembly, Lift Cylinders ..........................................................................................323 Installation, Main Lift Cylinders .................................................................................324 Installation, Free–Lift Cylinder ..................................................................................325 HEADER HOSE ARRANGEMENTS H/S/E/J2.00–3.20XM (H/S/E/J40–65XM) S/E/J2.00–3.00XL (S/E/J40–60XL) ..........................326 New Hose Installation, Two–Stage, LFL Mast ........................................................................326 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ........................................................326 New Hose Installation, Two–Stage FFL Mast .........................................................................330 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ........................................................330 New Hose Installation, Three–Stage FFL Mast .......................................................................334 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast .....................................................339 HEADER HOSE ARRANGEMENTS H/E1.50–1.75XM, H/S2.00XMS (H/S/E25–35XM, H/S/E40XMS) and J1.60–2.00XMT (J30–40XMT) ..........341 New Hose Installation, Two–Stage LFL Mast .........................................................................342 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ........................................................342 New Hose Installation, Two–Stage FFL Mast .........................................................................345 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ........................................................345 New Hose Installation, Three–Stage, FFL Mast ......................................................................349 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast .....................................................354 CHECKS AND ADJUSTMENTS ....................................................................................................355 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ..........................................................................355 Check The Lift Cylinders For Leaks ...............................................................................355 Check The Tilt Cylinders For Leaks ...............................................................................355 ADJUST THE TILT CYLINDERS ............................................................................................355 ADJUST THE LIFT CHAINS ...............................................................................................356 ADJUST THE MAST ......................................................................................................357 ADJUST THE CARRIAGE ..................................................................................................358 TROUBLESHOOTING............................................................................................................359 INTRODUCTION...............................................................................................................360 GENERAL................................................................................................................360 DESCRIPTION............................................................................................................361 Hydraulic System...................................................................................................361 OPERATION..............................................................................................................361 Hydraulic System...................................................................................................361 Hydraulic Gear Pump................................................................................................362 Rotator Actuator Valve.............................................................................................362 Steering Pump......................................................................................................365 REPAIRS....................................................................................................................369 HYDRAULIC TANK.........................................................................................................369 E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal....................................................................369 J2.00-3.20XM (J40-65XM) Tank Removal...............................................................................369 Tank Inspection....................................................................................................369 Tank Repairs, Small Leaks..........................................................................................370 Tank Repairs, Large Leaks .........................................................................................370 Tank Cleaning......................................................................................................370 Steam Method Of Cleaning Tank......................................................................................370 Chemical Solution Method Of Cleaning Tank..........................................................................370 Additional Preparations For Tank repair............................................................................371 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation...............................................................371 J2.00-3.20XM (J40-65XM) Tank Installation..........................................................................371 FILTER REPLACEMENT.....................................................................................................372 HYDRAULIC PUMP.........................................................................................................372 Removing E1.50-3.20XM (E25-65XM) and N30XMH Hydraulic Pump.........................................................372 Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump..................................................................373 Pump Seal Replacement And Pump Assembly............................................................................373 Assemble Pump On The Motor.........................................................................................375 Install The Hydraulic Pump And Motor Assembly [E1.50-3.20XM (E25-65XM) and N30XMH].................................376 Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly..................................................376 MAIN CONTROL VALVE.....................................................................................................377 STEERING PUMP..........................................................................................................377 Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N30XMH...................................................377 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM)..............................................................378 Pump Assembly And Installation.....................................................................................379 ROTARY ACTUATOR VALVE..................................................................................................380 Disassembly, Cleaning and Inspection...............................................................................380 Assembly...........................................................................................................380 STEERING CONTROL UNIT..................................................................................................380 Control Unit Removal...............................................................................................381 Control Unit Installation..........................................................................................381 STEERING CYLINDER......................................................................................................381 CHECKS AND ADJUSTMENTS.....................................................................................................383 MAIN CONTROL VALVE.....................................................................................................383 STEERING RELIEF VALVE..................................................................................................383 TROUBLESHOOTING CHART......................................................................................................383 SPECIFICATIONS.............................................................................................................387 INTRODUCTION...............................................................................................................390 GENERAL................................................................................................................390 LEAD-ACID BATTERIES....................................................................................................390 SPECIFIC GRAVITY.......................................................................................................391 CHEMICAL REACTION IN A CELL............................................................................................391 ELECTRICAL TERMS.......................................................................................................392 HOW TO SELECT THE BATTERY..............................................................................................392 VOLTAGE OF A BATTERY...................................................................................................392 THE BATTERY AS A COUNTERWEIGHT.........................................................................................393 BATTERY RATINGS........................................................................................................393 Kilowatt-Hours.....................................................................................................394 BATTERY MAINTENANCE........................................................................................................394 SAFETY PROCEDURES......................................................................................................394 MAINTENCE RECORDS......................................................................................................395 THE NEW BATTERY........................................................................................................395 HOW TO CLEAN THE BATTERY...............................................................................................396 HOW TO ADD WATER.......................................................................................................396 THE HYDROMETER.........................................................................................................397 BATTERY TEMPERATURE....................................................................................................397 CHARGING THE BATTERY...................................................................................................398 Types Of Battery Charges...........................................................................................399 Methods Of Charging................................................................................................400 Troubleshooting The Charger........................................................................................400 How to Know When The Battery Is Fully Charged......................................................................401 WHERE TO CHARGE THE BATTERIES..........................................................................................401 Equipment Needed...................................................................................................401 BATTERY CONNECTORS.....................................................................................................402 BATTERY CARE...........................................................................................................402 INTRODUCTION...............................................................................................................404 GENERAL................................................................................................................404 DESCRIPTION............................................................................................................404 REPAIRS....................................................................................................................408 REMOVAL AND DISASSEMBLY................................................................................................408 ASSEMBLY AND INSTALLATION..............................................................................................408 INTRODUCTION...............................................................................................................411 GENERAL................................................................................................................411 DESCRIPTION............................................................................................................411 OPERATION..............................................................................................................412 E1.50-3.20XM (E25-65XM)............................................................................................413 J2.00-3.20XM (J40-65XM)............................................................................................413 Lift Section.......................................................................................................413 Tilt Section.......................................................................................................414 Relief Valve.......................................................................................................416 REPAIRS....................................................................................................................417 MAIN CONTROL VALVE.....................................................................................................417 Removal............................................................................................................417 Disassembly........................................................................................................417 Cleaning And Inspection............................................................................................417 Assembly...........................................................................................................417 Installation, E1.50-3.20XM (E25-65XM)..............................................................................419 Installation, J2.00-3.20XM (J40-65XM)..............................................................................421 CONTROL LEVER LINKAGE, E1.50-3.20XM (E25-65XM).........................................................................422 Removal............................................................................................................422 Disassembly........................................................................................................423 Assembly And Installation..........................................................................................423 CONTROL VALVE LINKAGE, E1.50-3.20XM (E25-65XM).........................................................................423 Removal And Disassembly............................................................................................423 Assembly And Installation..........................................................................................424 CONTROL LEVER LINKAGE, J2.00-3.20XM (J40-65XM).........................................................................424 Removal............................................................................................................424 Disassembly........................................................................................................424 Assembly And Installation..........................................................................................426 CHECKS AND ADJUSTMENTS.....................................................................................................427 PRESSURE RELIEF VALVES.................................................................................................427 Primary Relief Valve...............................................................................................427 Secondary Relief Valve.............................................................................................427 TROUBLESHOOTING............................................................................................................428 INTRODUCTION...............................................................................................................430 GENERAL................................................................................................................430 SERIAL NUMBER DATA.....................................................................................................430 HOW TO MOVE A DISABLED LIFT TRUCK......................................................................................430 How To Tow A Lift Truck ...........................................................................................430 HOW TO PUT A LIFT TRUCK ON BLOCKS......................................................................................431 How To Raise The Drive Tires.......................................................................................431 How To Raise The Steering Tires....................................................................................431 MAINTENANCE SCHEDULE.......................................................................................................432 MAINTENANCE PROCEDURES.....................................................................................................435 EVERY 8 HOURS OR DAILY.....................................................................................................435 Tires And Wheels.......................................................................................................435 Forks..................................................................................................................436 Fork Adjustment........................................................................................................436 Fork Removal...........................................................................................................436 Fork Installation......................................................................................................437 Inspection Of Forks, Mast And Lift Chains..............................................................................437 Safety Labels..........................................................................................................438 Steering Column Latch..................................................................................................438 Operator Restraint System..............................................................................................439 Battery Restraint System, E25-65XM, E25-65XM2.........................................................................439 Battery Restraint System - J40-65XM-65XM, J40-65XM2...................................................................440 Battery................................................................................................................440 Hydraulic System.......................................................................................................441 HOW TO MAKE CHECKS WITH THE KEY "ON"...................................................................................442 Gauges, Horn And Fuses.............................................................................................442 Steering System....................................................................................................442 Service Brake......................................................................................................442 Parking Brake......................................................................................................443 Control Levers And Pedals..........................................................................................443 Lift System Operation..............................................................................................443 EVERY 350 HOURS OR THREE MONTHS ...........................................................................................444 HYDRAULIC TANK BREATHER................................................................................................444 DIFFERENTIAL AND SPEED REDUCER.........................................................................................444 WHEEL NUT TORQUES......................................................................................................445 STEERING AXLE SPINDLES.................................................................................................445 MAST...................................................................................................................445 LIFT CHAINS............................................................................................................446 Check For Wear.....................................................................................................446 Lubrication........................................................................................................446 FORKS..................................................................................................................446 BRAKE FLUID............................................................................................................447 OTHER LUBRICATION......................................................................................................447 SEAT BRAKE (E25-65XM, E25-65XM2 Only...................................................................................447 ELECTRICAL INSPECTION..................................................................................................447 Contactors.........................................................................................................448 Motor Brushes......................................................................................................448 Motor Brushes, General.............................................................................................448 EVERY 2000 HOURS OR YEARLY.................................................................................................458 HYDRAULIC SYSTEM.......................................................................................................458 Change The Filter For The Hydraulic Oil............................................................................458 Change The Hydraulic Oil...........................................................................................459 DIFFERENTIAL AND SPEED REDUCER.........................................................................................459 SERVICE BRAKES.........................................................................................................459 CONTACTORS.............................................................................................................460 WHEEL BEARINGS.........................................................................................................460 Steer Wheels, Lubrication..........................................................................................460 Drive Wheels, Lubrication..........................................................................................460 LIFT CHAINS............................................................................................................460 GENERAL PROCEDURE..........................................................................................................460 HOW TO CHARGE THE BATTERY..............................................................................................460 HOW TO CHANGE THE BATTERY..............................................................................................462 General............................................................................................................462 Change The E25-65XM, E25-65XM2 Battery.............................................................................462 Change The J40-65XM, J40-65XM2 Battery.............................................................................464 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM............................................................................466 Check The Lift Cylinders For Leaks.................................................................................466 Check The Tilt Cylinders For Leaks.................................................................................466 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)..................................................................467 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)..................................................................468 LIFT CHAIN ADJUSTMENTS.................................................................................................468 HOW TO CHECK THE PMT CIRCUIT...........................................................................................469 WELDING REPAIRS........................................................................................................470 CHANGES TO THE OVERHEAD GUARD..........................................................................................470 TIRES AND WHEELS, E25-65XM, E25-65XM2..................................................................................470 Remove The Wheels From The Lift Truck.............................................................................471 Remove And Install The Tire On The Wheel...........................................................................471 PNEUMATIC TIRES AND WHEELS J40-65XM, J40-65XM2.........................................................................471 Remove The Wheels From The Lift Truck..............................................................................471 Remove The Wheel From The Pneumatic Tire...........................................................................472 Install The Wheel In The Pneumatic Tire............................................................................473 Add Air To The Tires...............................................................................................474 Install The Wheels.................................................................................................474 SOLID RUBBER TIRES ON PNEUMATIC WHEELS.................................................................................474 Remove The Wheels From The Lift Truck..............................................................................474 Remove The Solid Rubber Tire From The Pneumatic Wheel..............................................................474 Install The Solid Rubber Tire On The Pneumatic Wheel...............................................................476 Install The Wheels ................................................................................................476 REFERENCE TABLE............................................................................................................477 Adhesive And Sealants .................................................................................................477 INTRODUCTION...............................................................................................................478 NOMENCLATURE, THREADS..................................................................................................478 STRENGTH IDENTIFICATION................................................................................................479 TABLE 1. BOLTS AND SCREWS..................................................................................................479 TABLE 2. STUDS AND NUTS....................................................................................................480 TABLE 3. TORQUE NUTS.......................................................................................................481 TABLE 4. TORQUE NUTS WITH NYLON INSERT.....................................................................................482 TABLE 5. TORQUE VALUES FOR INCH FASTENERS..................................................................................483 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS................................................................................484 INTRODUCTION...............................................................................................................487 GENERAL................................................................................................................487 DESCRIPTION............................................................................................................487 REPAIRS....................................................................................................................488 STEERING AXLE ASSEMBLY.................................................................................................488 Removal............................................................................................................488 Installation.......................................................................................................489 WHEELS AND HUBS........................................................................................................489 Removal and Disassembly............................................................................................489 Cleaning...........................................................................................................491 Assembly And Installation..........................................................................................491 SPINDLES, BEARINGS AND LINKS...........................................................................................491 Removal And Disassembly............................................................................................491 Cleaning and Inspection............................................................................................492 Assembly and Installation..........................................................................................492 TORQUE SPECIFICATIONS......................................................................................................493 TROUBLESHOOTING............................................................................................................494 INTRODUCTION...............................................................................................................495 GENERAL................................................................................................................495 DESCRIPTION............................................................................................................495 OPERATION..............................................................................................................495 REPAIRS....................................................................................................................496 STEERING WHEEL AND COLUMN ASSEMBLY.....................................................................................496 Removal of the Assembly Components.................................................................................500 Disassembly of the Steering Control Unit...........................................................................501 Cleaning of the Steering Control Unit..............................................................................501 Assembly of the Steering Control Unit..............................................................................501 Installation of the Steering Control Unit..........................................................................501 Installation of the Assembly Components............................................................................501 CHECKS AND ADJUSTMENTS.....................................................................................................509 REMOVE AIR FROM THE SYSTEM.............................................................................................509 TROUBLESHOOTING............................................................................................................509 STEERING SYSTEM............................................................................................................511 GENERAL................................................................................................................511 DESCRIPTION............................................................................................................513 STEERING WHEEL AND COLUMN ASSEMBLY.....................................................................................514 Removal Of The Assembly Components.................................................................................514 Installation Of The Assembly Components............................................................................518 POWER STEERING MOTOR AND PUMP..............................................................................................519 DESCRIPTION............................................................................................................519 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM).....................519 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)..........................................................519 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM).......................................................................520 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)......................................................................522 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS).....................................................................523 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)].........................523 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM).....................................................................524 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)...................................................................526 REPAIRS, POWER STEERING PUMP...........................................................................................527 Seal Replacement...................................................................................................528 HYDRAULIC STEERING MOTOR...................................................................................................528 DESCRIPTION............................................................................................................528 REPAIRS, HYDRAULIC STEERING MOTOR......................................................................................529 Removal ...........................................................................................................529 Disassembly........................................................................................................529 Cleaning And Inspection............................................................................................529 Assembly...........................................................................................................530 Installation, Hydraulic Steering Motor.............................................................................531 CHECKS AND ADJUSTMENTS.....................................................................................................531 AIR IN THE STEERING SYSTEM.............................................................................................531 CHECK STEERING PRESSURE................................................................................................531 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)..........................................................532 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS..........................................................................533 TROUBLESHOOTING............................................................................................................535 INTRODUCTION...............................................................................................................538 GENERAL................................................................................................................538 DESCRIPTION............................................................................................................538 REPAIRS....................................................................................................................538 REMOVAL................................................................................................................538 DISASSEMBLY............................................................................................................538 CLEANING...............................................................................................................538 ASSEMBLY...............................................................................................................538 Tilt Cylinders with O-Rings or Single Lip Seals....................................................................538 Tilt Cylinders for the XM and XMS Models...........................................................................539 Tilt Cylinders for H700 800A and Early Model H700 920B.............................................................541 INSTALLATION...........................................................................................................541 Tilt Cylinders Using Chevron Packing...............................................................................542 CHECKS AND ADJUSTMENTS.....................................................................................................544 CHECK THE TILT CYLINDERS FOR LEAKS.....................................................................................544 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE................................................................544 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS...................................................................545 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS..................................................................546 TROUBLESHOOTING............................................................................................................548
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.
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