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Hyster E25 60XL service manual – PDF DOWNLOAD
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Description
Hyster E25 60XL service manual
File Details:
Hyster E25 60XL service manual
Language : English
Pages : 581
Size : 15.61 MB
Downloadable : Yes
Format : PDF
HYSTER E25 60XL SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster E25 60XL service manual
- Shop Repair Manual. The Service workshop repair manual offers detailed servicing instructions and will give you complete step by step information on repair, servicing, preventative maintenance & troubleshooting procedures for your Hyster Fork Lift. This comprehensive service manual features photos and illustrations along with step-by-step instructions that will guide you through the entire repair process. This manual contains all you need to know to keep your Hyster Fork Lift working correctly. You will find that this manual is a indispensable source of detailed maintenance and repair information and is the only service repair manual you will need for your Hyster Fork Lift It will help you better understand, care for, service and overall will lower the repair and maintenance cost for your Hyster Fork Lift.
Table of Contents:
Hyster E25 60XL service manual
INTRODUCTION................................................................................................................................ 1 GENERAL................................................................................................................................. 1 INDICATORS WITH METER MOVEMENTS......................................................................................................... 2 BATTERY INDICATORS WITH LCD OR LED DISPLAYS............................................................................................. 3 Liquid Crystal Displays............................................................................................................. 3 Light Emitting Diode Displays....................................................................................................... 7 CHECKS AND ADJUSTMENTS...................................................................................................................... 9 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS................................................................................. 9 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.................................................................................... 9 Reset Potentiometer................................................................................................................. 9 Specific Gravity Alarm.............................................................................................................. 10 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS................................................................................. 11 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.................................................................................... 11 Reset Potentiometer................................................................................................................. 11 Discharge Potentiometer............................................................................................................. 11 LED DISPLAY WITH LIFT INTERRUPT......................................................................................................... 12 CHECKING CURTIS 933-1 METER............................................................................................................. 12 Reset Check......................................................................................................................... 12 Discharge Check..................................................................................................................... 13 Lockout Check....................................................................................................................... 13 LED's Do Not Illuminate............................................................................................................. 14 Hourmeter Check..................................................................................................................... 14 Hour Glass Icon..................................................................................................................... 14 ADJUSTMENT OF CURTIS 933-1 METER.................................................................................................... 14 CHECKING CURTIS 1215 BATTERY INDICATOR.............................................................................................. 14 ADJUSTING CURTIS 1215 BATTERY INDICATOR............................................................................................. 15 Voltage Selection............................................................................................................... 16 ADJUSTING BDI OF SEM DISPLAY PANEL.................................................................................................. 17 REPAIRS................................................................................................................................. 17 BATTERY INDICATORS.................................................................................................................. 17 Replacement..................................................................................................................... 17 CONTROLLER FOR THE BATTERY INDICATOR................................................................................................ 17 Replacement..................................................................................................................... 17 DISPLAY PANEL COMPONENTS............................................................................................................ 17 REPLACING SEM DISPLAY PANEL......................................................................................................... 17 SEM Display Panel REMOVAL........................................................................................................... 19 Removal And Replacement......................................................................................................... 19 INTRODUCTION................................................................................................................................ 21 GENERAL................................................................................................................................. 21 DESCRIPTION AND OPERATION............................................................................................................... 21 REPAIRS..................................................................................................................................... 22 MASTER CYLINDER......................................................................................................................... 22 Removal And Disassembly............................................................................................................. 22 Inspection.......................................................................................................................... 23 Assembly............................................................................................................................ 23 BRAKES, E/J1.25-1.75XL(E25-35XL)........................................................................................................ 23 Removal And Disassembly............................................................................................................. 24 Cleaning Procedures................................................................................................................. 25 Inspection.......................................................................................................................... 25 Assembly And Installation........................................................................................................... 26 Adjust The Service Brakes........................................................................................................... 27 Adjust The Parking Brake............................................................................................................ 27 Remove The Air From The Brake System................................................................................................ 27 BRAKES, E/J2.00-3.00XL (E/J40-60XL)..................................................................................................... 28 Removal And Disassembly............................................................................................................. 28 Cleaning Procedures................................................................................................................. 28 Inspection.......................................................................................................................... 30 Assembly............................................................................................................................ 30 Adjust The Service Brakes........................................................................................................... 33 Adjust The Parking Brake............................................................................................................ 34 Remove The Air From The Brake System................................................................................................ 34 SEAT BRAKE.................................................................................................................................. 35 REPAIRS................................................................................................................................. 35 Inspection.......................................................................................................................... 35 Removal............................................................................................................................. 36 Installation........................................................................................................................ 36 Seat Brake Adjustments.............................................................................................................. 38 SPECIFICATIONS.............................................................................................................................. 39 TROUBLESHOOTING............................................................................................................................. 39 BATTERY SPECIFICATIONS...................................................................................................................... 42 WHEELS AND TIRES............................................................................................................................ 43 HYDRAULIC SYSTEM............................................................................................................................ 43 CAPACITIES.................................................................................................................................. 44 UPRIGHT SPEEDS E/J1.25-1.75XL (E25-35XL) (36-48 volt)....................................................................................... 44 UPRIGHT SPEEDS E/J1.25-1.75XL (E25-35XL)(36-48 volt)........................................................................................ 45 UPRIGHT SPEEDS E/J2.00-3.00XL (E/J40-60XL) (36-48 volt)..................................................................................... 46 UPRIGHT SPEEDS E/J2.00-3.00XL (E/J40-60XL) (72-80 volt)..................................................................................... 47 TORQUE SPECIFICATIONS....................................................................................................................... 48 TORQUE SPECIFICATIONS....................................................................................................................... 49 EV-100 MOTOR CONTROLLER ADJUSTMENTS (SCR CONTROL FOR HYDRAULIC PUMP)........................................................................ 49 CABLEFORM MARK XI MOTOR CONTROLLER.......................................................................................................... 50 UPRIGHT SPEEDS J25-35B (24-36 volt)......................................................................................................... 51 INTRODUCTION................................................................................................................................ 52 ELECTRIC MOTOR MAINTENANCE, GENERAL..................................................................................................... 52 BRUSH AND COMMUNICATOR INSPECTION....................................................................................................... 52 Hydraulic Pump Motor And Traction Motor............................................................................................. 52 Steering Pump Motor................................................................................................................. 54 BRUSH WEAR REPLACEMENT GUIDE................................................................................................................ 54 Commutator Problems..................................................................................................................... 56 BRUSH REPLACEMENTS...................................................................................................................... 58 DISASSEMBLY OF MOTORS................................................................................................................... 60 Traction Motor And Hydraulic Pump Motor............................................................................................. 60 Steering Pump Motor................................................................................................................. 66 ASSEMBLY OF MOTORS...................................................................................................................... 68 Traction Motor And Hydraulic Pump Motor ............................................................................................ 68 Steering Pump Motor................................................................................................................. 68 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS.......................................................................................... 68 TESTS FOR A DAMAGED FIELD AND ARMATURE.................................................................................................. 69 Test For An Open Circuit In The Armature............................................................................................ 69 Test For A Short-Circuit In One Armature Winding.................................................................................... 69 Test For A Short-Circuit To Armature Shaft.......................................................................................... 70 Test For An Open Circuit In A Field Coil............................................................................................ 70 Test For A Short-Circuit In A Field Coil............................................................................................ 70 Test For A Short-Circuit Between The Field And The Motor Case....................................................................... 71 Brush Holder Test................................................................................................................... 71 TROUBLESHOOTING............................................................................................................................. 71 FIGURE 1. EV-100 "LX" SERIES TRACTION SCHEMATIC DIAGRAM..................................................................................... 74 FIGURE 2. EV-100 "LX" SERIES BATTERY INDICATOR W/O LIFT INTERRUPT W/PUMP MOTOR SCR CONTROL SCHEMATIC........................................ 75 FIGURE 3. EV-100 "LX" SERIES BATTERY INDICATOR W/O LIFT INTERRUPT W/O PUMP MOTOR SCR CONTROL SCHEMATIC...................................... 76 FIGURE 4. EV-100 "LX" SERIES BATTERY INDICATOR W/LIFT INTERRUPT W/PUMP MOTOR SCR CONTROL SCHEMATIC.......................................... 77 FIGURE 5. EV-100 "LX" SERIES BATTERY INDICATOR W/LIFT INTERRUPT, W/O PUMP MOTOR SCR CONTROL SCHEMATIC....................................... 78 FIGURE 6. EV-100 "LX" SERIES W/BWI DISPLAY AND W/LIFT INTERRUPT - W/PUMP MOTOR SCR CONTROL SCHEMATIC........................................ 80 FIGURE 7. EV-100 "LX" SERIES WITH GE OR ITW DISPLAY W/LIFT INTERRUPT - W/O PUMP MOTOR SCR CONTROL SCHEMATIC................................. 82 FIGURE 8. EV-100 "LX" SERIES W OR W/O "ON-DEMAND" STEERING WIRING DIAGRAM................................................................... 84 FIGURE 9. EV-100 "LX" SERIES W/O REGEN OR FIELD WEAKENING AND W/O PUMP MOTOR SCR CONTROL WIRING DIAGRAM..................................... 86 FIGURE 10. EV-100 "LX" SERIES W/REGEN AND/OR FIELD WEAKENING AND SCR PUMP WIRING DIAGRAM.................................................... 88 FIGURE 11. EV-100 "LX" SERIES BATTERY INDICATOR W/O LIFT INTERRUPT AND W/PUMP MOTOR SCR CONTROL WIRING DIAGRAM.............................. 89 FIGURE 12. EV-100 "LX" SERIES BATTERY INDICATOR W/LIFT INTERRUPT AND W/PUMP MOTOR SCR CONTROL AND W/LIFT INTERRUPT, WIRING DIAGR............ 90 FIGURE 13. EV-100 "LX" SERIES BATTERY INDICATOR W/AND W/O LIFT INTERRUPT W/O PUMP MOTOR SCR CONTROL WIRING DIAGRAM.......................... 92 FIGURE 14. EV-100 "LX" SERIES GE BATTERY INDICATOR W/BWI DISPLAY AND W/LIFT INTERRUPT W/PUMP MOTOR SCR CONTROL WIRING DIAGRAM............... 93 FIGURE 15. EV-100 "LX" SERIES I.T.W. (LED) DASH DISPLAY WIRING DIAGRAM...................................................................... 94 FIGURE 1. SCHEMATIC DIAGRAM, EV-100 MOTOR CONTROLLER, (AFTER NOVEMBER 1987)................................................................. 96 FIGURE 2. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITHOUT LIFT INTERRUPT AND SCR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER NOVEMBER ............ 98 FIGURE 3. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITHOUT LIFT INTERRUPT AND WITH CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTE............ 99 FIGURE 4. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITH LIFT INTERRUPT AND WITH SCR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER NOVEMBE............100 FIGURE 5. SCHEMATIC DIAGRAM, BATTERY INDICATOR WITH LIFT INTERRUPT AND WITH CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER N............101 FIGURE 6. SCHEMATIC DIAGRAM, LED DISPLAY WITH LIFT INTERRUPT AND WITH SCR CONTROL FOR HYDRAULIC PUMP MOTOR, (AFTER NOVEMBER 1987............102 FIGURE 7. WIRE DIAGRAM, CONTROL SWITCHES (AFTER NOVEMBER 1987)..............................................................................103 FIGURE 8. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITH CONTACTOR CONTROL FOR HYDRAULIC PUMP MOTOR (AFTER NOVEMBER 1987).......................105 FIGURE 9. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITH REGENERATIVE BRAKING, SCR CONTROL FOR HYDRAULIC PUMP MOTOR AND FIELD WEAKEN............106 FIGURE 10. WIRE DIAGRAMS, BATTERY INDICATORS (AFTER NOVEMBER 1987)..........................................................................107 FIGURE 11. WIRE DIAGRAMS, BATTERY INDICATORS (AFTER NOVEMBER 1987)..........................................................................108 FIGURE 12. SCHEMATIC DIAGRAM, EV-100 MOTOR CONTROLLER WITH REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987).....................................109 FIGURE 13. SCHEMATIC DIAGRAM, EV-100 MOTOR CONTROLLER WITHOUT REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987)..................................111 FIGURE 14. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITH REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987)..........................................113 FIGURE 15. WIRE DIAGRAM, EV-100 MOTOR CONTROLLER WITHOUT REGENERATIVE BRAKING, (BEFORE NOVEMBER 1987).......................................115 FIGURE 16. WIRE DIAGRAM, CONTROL SWITCHES (BEFORE NOVEMBER 1987)............................................................................117 FIGURE 17. WIRE DIAGRAMS, BATTERY INDICATORS (BEFORE NOVEMBER 1987).........................................................................119 FIGURE 18. HYDRAULIC SCHEMATIC, ALL MODELS..................................................................................................120 INTRODUCTION................................................................................................................................121 GENERAL.................................................................................................................................121 DESCRIPTION.............................................................................................................................121 REPAIRS.....................................................................................................................................123 REMOVAL OF THE DRIVE AXLE...............................................................................................................123 Disassembly of the Drive Axle.......................................................................................................124 Disassembly of the Transmission and Differential....................................................................................125 CLEANING................................................................................................................................127 INSPECTION..............................................................................................................................127 ASSEMBLY................................................................................................................................127 Assembly Of The Transmission And Differential.......................................................................................127 Assembly Of The Drive Axle..........................................................................................................133 INSTALLATION OF THE DRIVE AXLE ASSEMBLY.................................................................................................134 TROUBLESHOOTING.............................................................................................................................135 TORQUE SPECIFICATIONS.......................................................................................................................136 ELECTRICAL CHECKS AND ADJUSTMENTS FOR SitDrive) ELECTRICAL LIFT TRUCKS......................................................................137 GENERAL.................................................................................................................................137 CONTROL AND POWER FUSES.................................................................................................................142 CONTROL CARD ADJUSTMENTS................................................................................................................143 Adjusting Creep Speed, "CREEP'......................................................................................................145 Adjusting Controlled Acceleration, "C/A" ...........................................................................................145 Adjusting Current Limit, "C/L"......................................................................................................146 Adjust "1A TIME"....................................................................................................................147 Adjust 1A Drop Out, "1A D.O"........................................................................................................149 Adjust Plugging, "PLUG".............................................................................................................149 Ramp Start..........................................................................................................................149 Adjust Field Weakening Pick Up and Drop Out, "F.W.P.U." And "F.W.D.O."..............................................................149 Adjust "REGEN C/L" (Current Limit)..................................................................................................150 Adjust "REGEN D.O." (Drop Out)......................................................................................................150 PROPORTIONAL CONTROL (J25-35A Only).....................................................................................................153 SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS.................................................................................................154 SCR CONTROL, SINGLE PUMP MOTOR..........................................................................................................154 Accelerator Card (E-20-100B, J40-60AS Only).........................................................................................155 Circuit Description For Accelerator Card Used With A Seat Switch....................................................................156 Accelerator "START" (IC3)...........................................................................................................157 Accelertor "1A TIME" (IC2)..........................................................................................................157 Circuit Description For Accelerator Card Used With A Seat Brake.....................................................................157 Accelerator "START" (IC3)...........................................................................................................158 Accelerator "1A TIME" (IC1 and IC2).................................................................................................158 CHECK THE ACCELERTOR CARD...........................................................................................................158 ADJUSTING THE ACCELERATOR CARD......................................................................................................158 THE POTENTIOMETERS AND CONTOL SWITCHES..................................................................................................158 Steering Potentiometer (J25-35A Only)...............................................................................................158 Accelerator Potentiometer And Start Switch (E20-120XL And J25-60XL Only)............................................................160 Accelerator Potentiometer And Direction Switch......................................................................................161 Adjusting Start Switch..............................................................................................................162 "FORWARD" And "REVERSE" Switch (MONOTROL) (Earlier Production Lift Trucks)..........................................................162 Direction Switches (MONOTROL) (Later Production Lift Trucks)........................................................................163 "FORWARD" And "REVERSE" Switch (Steering Column)....................................................................................164 Hydraulic Pump Switch...............................................................................................................164 Replace The Key Switch..............................................................................................................164 Adjust The Seat Switch..............................................................................................................164 Adjust The Brake Switch.............................................................................................................165 Parking Brake Switch................................................................................................................165 Rocker Switch.......................................................................................................................166 HYDRAULIC PUMP SOFT START (E100-120B Only) (72/80 Volt Only)............................................................................167 EV-100E MOTOR CONTROLLER, DESCRIPTION AND OPERATION.........................................................................................168 GENERAL.................................................................................................................................168 ELECTRONIC SPEED CONTROLS...............................................................................................................169 The Silicon Controlled Rectifier (SCR)..............................................................................................169 A Motor Circuit That Operates With Pulses...........................................................................................170 Traction Circuit....................................................................................................................172 Hydraulic Motor Circuit.............................................................................................................172 The SCR 1 "OFF" Circuit.............................................................................................................172 INDUCTION CURRENT FROM THE MOTOR........................................................................................................174 THE CONTROL CARD........................................................................................................................179 Pulse Monitor Trip (PMT) (Traction Circuit Only)....................................................................................180 SRO Circuit (Traction Circuit Only).................................................................................................181 Control Card Adjustments (Traction Circuit).........................................................................................181 Accelerator Control.................................................................................................................185 Dual Motor "Plugging" (J25-35B).....................................................................................................185 SCR CONTROL (HYDRAULIC PUMP MOTOR)......................................................................................................186 CONTACTORS AND ELECTRONIC DRIVERS (TRACTION CIRCUIT)....................................................................................187 The Electronic Drivers..............................................................................................................187 Contactors..........................................................................................................................188 CIRCUIT PROTECTION......................................................................................................................189 Current Limit.......................................................................................................................189 Thermal Protection..................................................................................................................189 Suppressors.........................................................................................................................189 Traction Circuit Fuse...............................................................................................................190 SEQUENCE OF OPERATION.......................................................................................................................190 EV-100 MOTOR CONTROLLER REPAIRS AND ADJUSTMENTS.............................................................................................203 GENERAL.................................................................................................................................203 FUSES...................................................................................................................................208 CONTROL CARD............................................................................................................................209 The Control Card Plugs..............................................................................................................211 HOW TO CHECK AN SCR.....................................................................................................................211 The SCR Assembly....................................................................................................................212 Thermal Protector...................................................................................................................212 How To Replace The SCR 1 Assembly...................................................................................................212 THE "OFF" CIRCUIT FOR SCR 1.............................................................................................................213 Check The Inductor Assembly.........................................................................................................213 Check Suppressors For SCR 2 And SCR 5...............................................................................................213 Check SCR 2 And SCR 5...............................................................................................................214 Replace The SCR 2 And SCR 5.........................................................................................................214 Check Capacitor C1..................................................................................................................215 DIODES D3 AND D4........................................................................................................................215 Check The Diodes D3 and D4..........................................................................................................215 Replacement, Diodes D3 and D4.......................................................................................................215 MOTOR CURRENT SENSOR....................................................................................................................215 THE ELECTRONIC DRIVER MODULE............................................................................................................215 CONTACTORS..............................................................................................................................216 CONTACTOR REPAIR........................................................................................................................217 Removing A Contactor Assembly.......................................................................................................217 Contactor Contacts..................................................................................................................217 Coil................................................................................................................................218 CONTROL CARD ADJUSTMENTS................................................................................................................220 "CREEP".............................................................................................................................220 "C/A" (Controlled Acceleration).....................................................................................................220 "C/L"...............................................................................................................................220 "1A TIME"...........................................................................................................................221 "PLUG"..............................................................................................................................222 "F.W.P.U. and "F.W.D.O."............................................................................................................222 "REGEN C/L".........................................................................................................................222 "REGEN D.O."........................................................................................................................222 VOLTAGE ADJUSTMENTS, SCR CONTROL FOR HYDRAULIC PUMP.....................................................................................222 INTRODUCTION................................................................................................................................226 GENERAL.................................................................................................................................226 SRO CIRCUIT AND PMT CIRCUIT (TRACTION CIRCUIT)..............................................................................................229 STATIC RETURN TO OFF (SRO) CIRCUIT......................................................................................................229 PULSE MONITOR TRIP (PMT)................................................................................................................229 THE SEQUENCE OF OPERATION (TRACTION CIRCUIT)............................................................................................229 CHECKING FOR THE CORRECT OPERATION......................................................................................................230 TROUBLESHOOTING.............................................................................................................................231 GENERAL PROCEDURES......................................................................................................................232 FAULT NUMBER 1. The Direction Contactors Will Not Close For Operation In Either Direction...........................................234 LIFT TRUCKS WITHOUT REGENERATIVE BRAKING....................................................................................................234 GENERAL PROCEDURES......................................................................................................................232 FAULT NUMBER 2. Lift Truck Will Not Move In Either Direction. The Direction Contactors Close And Then Immediately Open (PMT Fau....237 FAULT NUMBER 3. Lift Truck Will Not Move In Either Direction. The Direction Contactors Close Normally (No PMT Fault)................239 FAULT NUMBER 4. Lift Truck Will Not Move In One Direction. The Direction Contactors Close Normally (No PMT Fault)...................241 FAULT NUMBER 5. One Direction Contactor Will Not Close. Traction Circuit Operates Normally In Only One Direction...................241 FAULT NUMBER 6. Plugging Problems...................................................................................................242 FAULT NUMBER 7. Direction Contactors Close Normally. The Lift Truck Has Only Low Power Or Moves Slowly.............................243 FAULT NUMBER 8. Contactor 1a Will Not Energize. The Other Operations Of The Lift Truck Are Normal..................................244 FAULT NUMBER 1R. Regenerative Braking Contactor Does Not Close. The "forward" And "reverse" Contactors Will Close. The Lift Tr....245 LIFT TRUCKS EQUIPPED WITH REGENERATIVE BRAKING..............................................................................................245 GENERAL PROCEDURES......................................................................................................................232 FAULT NUMBER 2R. Lift Truck Will Not Move In Either Direction. The Direction Contactors Never Close. The Regenerative Braking ....246 FAULT NUMBER 3R. Lift Truck Will Not Move In One Direction. The Regenerative Braking Contactor Closes Normally. Direction Cont....248 FAULT NUMBER 4R. Lift Truck Will Not Move In Either Direction. The Regenerative Braking Contactor Closes. A Direction Contacto....249 FAULT NUMBER 5R. Lift Truck Will Not Move In Either Direction. The Regenerative Braking Contactor Closes. The Direction Contac....251 FAULT NUMBER 6R. One Direction Contactor Will Not Close. The Regenerative Braking Contactor Closes Normally. The Traction Circ....253 FAULT NUMBER 7R. Direction Contactors Close Normally. The Lift Truck Has Only Low Power Or Moves Slowly. The Regenerative Brak....255 FAULT NUMBER 8R. Contactor 1a Will Not Energize. The Other Operations Of The Lift Truck Are Normal.................................256 FAULT NUMBER 9R. The Field Weakening Contactor Will Not Energize (36-48 Volt Lift Trucks Only). The Other Operations Of The Lif....257 FAULT NUMBER 10R. Regenerative Braking And Plugging Problems........................................................................258 FAULT NUMBER 11R. The Hydraulic Pump Will Not Operate When Any Hydraulic Hand Lever Is Moved From The Neutral Position..............259 FAULT NUMBER 12R. The Hydraulic Pump Will Not Stop Operating When The Hydraulic Hand Levers Are Returned To The Neutral Position....260 FAULT NUMBER 13R. The Hydraulic Pump Will Not Operate When Only One Hydraulic Lever Is Moved From The Neutral Position. The Ope....261 INTRODUCTION................................................................................................................................262 General.................................................................................................................................262 DESCRIPTION.................................................................................................................................262 Diagnostic Control Card.................................................................................................................262 Status Codes........................................................................................................................264 Hand Set................................................................................................................................264 Instrument Panel Display................................................................................................................265 Hourmeter Functions.................................................................................................................265 Battery Indicator Functions.........................................................................................................265 Control Card Connections................................................................................................................266 CHECKS AND ADJUSTMENTS......................................................................................................................272 General.................................................................................................................................272 Function Codes......................................................................................................................272 Connecting The Control Card For Bench Checks And Adjustments........................................................................273 Connecting The Hand Set To A Control Card Installed In A Lift Truck.................................................................274 Checking And Adjusting Function Settings................................................................................................274 General.............................................................................................................................274 How To Connect And Check Hand Set ..................................................................................................274 How To Check And Adjust Functions...................................................................................................274 Function Descriptions...............................................................................................................275 Traction Control Cards (EV-100/200 LXT-LX)..........................................................................................275 Pump Control Card (EV-100/200 LXP)..................................................................................................279 Dual Motor Traction Control Card (EV-100 LXM).......................................................................................280 Function Tables.........................................................................................................................283 REPAIRS.....................................................................................................................................296 General.................................................................................................................................296 Control Card Plugs......................................................................................................................296 TROUBLESHOOTING.............................................................................................................................297 General.................................................................................................................................297 INTRODUCTION................................................................................................................................332 GENERAL.................................................................................................................................332 REPAIRS.....................................................................................................................................332 FORKS...................................................................................................................................332 CARRIAGE................................................................................................................................332 Removal.............................................................................................................................332 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................................333 Installation........................................................................................................................334 MAST....................................................................................................................................335 Removal.............................................................................................................................335 Disassembly.........................................................................................................................336 Cleaning............................................................................................................................339 Inspection, Forks, Mast, And Lift Chains............................................................................................339 Assembly, Mast Components...........................................................................................................340 Installation........................................................................................................................341 CHECKS AND ADJUSTMENTS......................................................................................................................342 CHECK FOR LEAKS IN THE LIFT SYSTEM......................................................................................................342 Check the Lift Cylinders for Leaks..................................................................................................342 Check The Tilt Cylinders For Leaks..................................................................................................342 ADJUST THE TILT CYLINDER STROKE AND BACKWARD TILT ANGLE.................................................................................342 LIFT CHAIN ADJUSTMENTS..................................................................................................................343 MAST ADJUSTMENTS........................................................................................................................343 CARRIAGE ADJUSTMENTS....................................................................................................................345 TROUBLESHOOTING.............................................................................................................................346 FRAME.......................................................................................................................................347 GENERAL.................................................................................................................................347 DESCRIPTION.............................................................................................................................347 BATTERY SPECIFICATIONS......................................................................................................................349 REPAIRS.....................................................................................................................................352 OVERHEAD GUARD..........................................................................................................................352 Removal.............................................................................................................................352 Installation........................................................................................................................352 BATTERY RESTRAINT AND SEAT ASSEMBLY.....................................................................................................353 COUNTERWEIGHT...........................................................................................................................357 Removal.............................................................................................................................357 Installation........................................................................................................................357 TRACTION MOTOR..........................................................................................................................358 Removal.............................................................................................................................358 Installation........................................................................................................................359 HYDRAULIC TANK..........................................................................................................................360 Inspection..........................................................................................................................360 Repairs, Small Leaks................................................................................................................360 Repairs, Large Leaks................................................................................................................360 Cleaning............................................................................................................................360 Steam Method Of Cleaning............................................................................................................360 Chemical Solution Method Of Cleaning................................................................................................361 Additional Preparations For Repair..................................................................................................361 PAINTING INSTRUCTIONS...................................................................................................................361 LABEL PLACEMENT.........................................................................................................................362 INTRODUCTION................................................................................................................................368 GENERAL.................................................................................................................................368 DESCRIPTION AND OPERATION...............................................................................................................368 Carriages...........................................................................................................................368 Mast Mounts.........................................................................................................................369 TWO-STAGE MAST, LIMITED FREE-LIFT.......................................................................................................370 Description and Operation...........................................................................................................370 TWO-STAGE MAST, FULL FREE-LIFT..........................................................................................................372 Description.........................................................................................................................372 Operation...........................................................................................................................372 THREE-STAGE, FULL FREE-LIFT MAST........................................................................................................374 Description.........................................................................................................................374 Operation...........................................................................................................................374 INTRODUCTION ...............................................................................................................................376 GENERAL ................................................................................................................................376 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ...............................................................................................376 REPAIRS ....................................................................................................................................377 FORKS ..................................................................................................................................377 Removal ............................................................................................................................377 Installation .......................................................................................................................378 CARRIAGES ..............................................................................................................................378 Removal, Standard Carriage .........................................................................................................378 Removal, Side–Shift Carriage .......................................................................................................379 Repairs ............................................................................................................................379 Installation, Standard Carriage ....................................................................................................379 Installation, Side–Shift Carriage ..................................................................................................380 MAST ...................................................................................................................................381 Removal ............................................................................................................................381 Disassembly, Three–Stage FFL Mast ..................................................................................................387 Disassembly, Two–Stage LFL And Two–Stage FFL Masts .................................................................................381 Cleaning and Inspection ............................................................................................................387 Assembly, Two–Stage LFL And Two–Stage FFL Mast .....................................................................................390 Assembly, Three–Stage FFL Mast .....................................................................................................391 Installation, Mast .................................................................................................................392 LIFT CYLINDERS .........................................................................................................................393 Removal, Main Lift Cylinders .......................................................................................................393 Removal, Free–Lift Cylinder ........................................................................................................393 Disassembly, Lift Cylinders ........................................................................................................393 Assembly, Lift Cylinders ...........................................................................................................394 Installation, Main Lift Cylinders ..................................................................................................395 Installation, Free–Lift Cylinder ...................................................................................................396 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) ...........................................397 New Hose Installation, Two–Stage, LFL Mast .........................................................................................397 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .........................................................................397 New Hose Installation, Two–Stage FFL Mast ..........................................................................................401 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .........................................................................401 New Hose Installation, Three–Stage FFL Mast ........................................................................................405 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ......................................................................410 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) ...........................412 New Hose Installation, Two–Stage LFL Mast ..........................................................................................413 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .........................................................................413 New Hose Installation, Two–Stage FFL Mast ..........................................................................................416 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .........................................................................416 New Hose Installation, Three–Stage, FFL Mast .......................................................................................420 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ......................................................................425 CHECKS AND ADJUSTMENTS .....................................................................................................................426 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ...........................................................................................426 Check The Lift Cylinders For Leaks ................................................................................................426 Check The Tilt Cylinders For Leaks ................................................................................................426 ADJUST THE TILT CYLINDERS .............................................................................................................426 ADJUST THE LIFT CHAINS ................................................................................................................427 ADJUST THE MAST .......................................................................................................................428 ADJUST THE CARRIAGE ...................................................................................................................429 TROUBLESHOOTING.............................................................................................................................430 HYDRAULIC SYSTEM............................................................................................................................431 GENERAL.................................................................................................................................431 DESCRIPTION.............................................................................................................................431 Hydraulic System....................................................................................................................431 OPERATION...............................................................................................................................432 Hydraulic System....................................................................................................................432 Hydraulic Pump......................................................................................................................433 Steering Pump.......................................................................................................................434 REPAIRS.....................................................................................................................................434 HYDRAULIC PUMP..........................................................................................................................434 Removal.............................................................................................................................434 Seal Placement......................................................................................................................435 Installation........................................................................................................................436 CHECKS AND ADJUSTMENTS......................................................................................................................436 MAIN CONTROL VALVE......................................................................................................................436 Linkage And Switches................................................................................................................436 Relief Valve........................................................................................................................437 STEERING RELIEF VALVE ..................................................................................................................438 TROUBLESHOOTING.............................................................................................................................440 SPECIFICATIONS..............................................................................................................................441 INTRODUCTION................................................................................................................................442 GENERAL.................................................................................................................................442 LEAD-ACID BATTERIES.....................................................................................................................442 SPECIFIC GRAVITY........................................................................................................................443 CHEMICAL REACTION IN A CELL.............................................................................................................443 ELECTRICAL TERMS........................................................................................................................444 HOW TO SELECT THE BATTERY...............................................................................................................444 VOLTAGE OF A BATTERY....................................................................................................................444 THE BATTERY AS A COUNTERWEIGHT..........................................................................................................445 BATTERY RATINGS.........................................................................................................................445 Kilowatt-Hours......................................................................................................................446 BATTERY MAINTENANCE.........................................................................................................................446 SAFETY PROCEDURES.......................................................................................................................446 MAINTENCE RECORDS.......................................................................................................................447 THE NEW BATTERY.........................................................................................................................447 HOW TO CLEAN THE BATTERY................................................................................................................448 HOW TO ADD WATER........................................................................................................................448 THE HYDROMETER..........................................................................................................................449 BATTERY TEMPERATURE.....................................................................................................................449 CHARGING THE BATTERY....................................................................................................................450 Types Of Battery Charges............................................................................................................451 Methods Of Charging.................................................................................................................452 Troubleshooting The Charger.........................................................................................................452 How to Know When The Battery Is Fully Charged.......................................................................................453 WHERE TO CHARGE THE BATTERIES...........................................................................................................453 Equipment Needed....................................................................................................................453 BATTERY CONNECTORS......................................................................................................................454 BATTERY CARE............................................................................................................................454 INTRODUCTION................................................................................................................................456 GENERAL.................................................................................................................................456 DESCRIPTION.................................................................................................................................456 GENERAL.................................................................................................................................456 STEERING COLUMN GAUGES, METERS AND INDICATORS...........................................................................................459 LED DISPLAY PANEL.......................................................................................................................459 Battery Discharge Indicators........................................................................................................459 Brush Wear Indicators...............................................................................................................460 Motor Temperature Indicators........................................................................................................461 "LX" SERIES DISPLAY PANEL...............................................................................................................462 Hourmeter Functions.................................................................................................................463 Battery Indicator Function..........................................................................................................463 Status Code Function................................................................................................................463 "ZX" SERIES DISPLAY PANELS..............................................................................................................463 Display Panel.......................................................................................................................464 Basic Display Panels................................................................................................................464 Performance Display.................................................................................................................466 Brush Wear Indicators...............................................................................................................469 CHECKS AND ADJUSTMENTS......................................................................................................................469 GENERAL.................................................................................................................................469 REPLACEMENT.................................................................................................................................470 GENERAL.................................................................................................................................470 METER REPLACEMENT.......................................................................................................................470 SENDER REPLACEMENT......................................................................................................................471 Fuel Level Sender...................................................................................................................471 Pressure And Temperature Sender.....................................................................................................471 I.T.W. DISPLAY PANEL....................................................................................................................472 Removal.............................................................................................................................472 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT...................................................................473 Removal.............................................................................................................................473 Replacing Display Panel Assembly....................................................................................................473 Indicator LEDs......................................................................................................................473 Battery Indicators..................................................................................................................473 Digital Display (Performance Disply Panel Only).....................................................................................473 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only).......................................473 Replacing Parts Of The Basic Display Panel..........................................................................................474 Replacing Parts Of The Performance Display Panel....................................................................................476 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT.......................................................................476 Removal And Replacement.............................................................................................................476 SPECIFICATIONS..............................................................................................................................477 TROUBLESHOOTING.............................................................................................................................478 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST................................................................................................479 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................................479 LIFT CYLINDERS..............................................................................................................................482 GENERAL.................................................................................................................................482 DESCRIPTION.............................................................................................................................482 Lowering Control Valve..............................................................................................................482 Cylinders (General).................................................................................................................485 Cylinders (H520-620B,H700-800A).....................................................................................................487 Cylinders (H360-460B)...............................................................................................................488 Cylinders (Two-Speed)...............................................................................................................488 REPAIRS.....................................................................................................................................489 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..................................................................................489 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................................489 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.............................................................493 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.......................................................491 DISASSEMBLY.............................................................................................................................491 ASSEMBLY................................................................................................................................493 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...........................................................................................493 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................................493 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead....................................................493 CHEVRON PACKING.........................................................................................................................494 LIFT CYLINDERS FOR VISTA MASTS..............................................................................................................497 DESCRIPTION.............................................................................................................................497 Lowering Control Valve..............................................................................................................499 REMOVAL.................................................................................................................................500 DISASSEMBLY.............................................................................................................................500 ASSEMBLY................................................................................................................................500 INSTALLATION............................................................................................................................501 Main Lift Cylinders.................................................................................................................501 Free-Lift Cylinders.................................................................................................................501 CHECKS AND ADJUSTMENTS......................................................................................................................502 CHECK FOR LEAKS IN LIFT SYSTEM..........................................................................................................502 TROUBLESHOOTING.............................................................................................................................503 SPECIFICATIONS..............................................................................................................................504 INTRODUCTION................................................................................................................................505 GENERAL.................................................................................................................................505 DESCRIPTION.............................................................................................................................505 OPERATION...............................................................................................................................506 Lift Section........................................................................................................................507 Tilt Section........................................................................................................................507 Relief Valve........................................................................................................................509 SOLENOID VALVE FOR AUXILIARY FUNCTION...................................................................................................510 Operation...........................................................................................................................510 REPAIRS.....................................................................................................................................510 MAIN CONTROL VALVE......................................................................................................................510 Removal and Disassembly.............................................................................................................510 Cleaning and Inspection.............................................................................................................511 Assembly............................................................................................................................511 Installation........................................................................................................................511 SOLENOID VALVE FOR AUXILIARY FUNCTION...................................................................................................511 Removal and Disassembly.............................................................................................................511 Assembly and Installation...........................................................................................................513 CHECKS AND ADJUSTMENTS......................................................................................................................513 PRESSURE RELIEF VALVES..................................................................................................................513 Primary Relief Valve................................................................................................................513 Seconday Relief Valve...............................................................................................................514 CONTROL LEVER ARRANGEMENT...............................................................................................................514 TROUBLESHOOTING.............................................................................................................................517 SPECIFICATIONS..............................................................................................................................519 INTRODUCTION................................................................................................................................520 GENERAL.................................................................................................................................520 HOW TO MOVE A DISABLED LIFT TRUCK.......................................................................................................520 How to Tow a Lift Truck.............................................................................................................520 HOW TO PUT A LIFT TRUCK ON BLOCKS ......................................................................................................521 How To Raise the Drive Tires........................................................................................................521 How To Raise the Steering Tires.....................................................................................................521 MAINTENANCE SCHEDULE........................................................................................................................522 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY...............................................................................................524 HOW TO MAKE CHECKS WITH KEY SWITCH OFF ................................................................................................524 Hydraulic System....................................................................................................................524 Battery.............................................................................................................................524 Battery Restraint System............................................................................................................525 Operator Restraint System...........................................................................................................526 Inspection Of The Mast, Forks And Lift Chains.......................................................................................526 Tires and Wheels....................................................................................................................528 Forks, Adjustment...................................................................................................................528 Forks, Removal And Installation.....................................................................................................528 SAFETY LABELS...........................................................................................................................529 HOW TO MAKE CHECKS WITH THE KEY SWITCH ON...............................................................................................529 Gauges and Horns....................................................................................................................529 Lift System Operation...............................................................................................................530 Service Brakes......................................................................................................................530 Parking Brake.......................................................................................................................530 Steering System.........................................................................................................................530 EVERY 350 HOURS OR TWO MONTHS...............................................................................................................531 HYDRAULIC TANK BREATHER.................................................................................................................531 STEERING TIE RODS, E/J1.25-1.75XL (E25-35XL) and J2.00-3.00XL (J40-60XL)................................................................531 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................531 WHEEL NUT TORQUES.......................................................................................................................531 STEERING AXLE SPINDLES, E/J2.00-3.00XL (E/J40-60XL) E3.50-5.50XL (E70-120XL)............................................................531 MAST....................................................................................................................................531 LIFT CHAINS.............................................................................................................................532 Check for Wear......................................................................................................................532 Lubrication.........................................................................................................................533 FORKS...................................................................................................................................533 BRAKE FLUID.............................................................................................................................533 OTHER LUBRICATION.......................................................................................................................533 SEAT BRAKE..............................................................................................................................533 ELECTRICAL INSPECTION...................................................................................................................533 Contactors..........................................................................................................................534 Motor Brushes.......................................................................................................................534 EVERY 2000 HOURS OR YEARLY..................................................................................................................537 HYDRAULIC SYSTEM........................................................................................................................537 Change the Filter for the Hydraulic Oil.............................................................................................537 Change the Hydraulic Oil............................................................................................................538 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................538 SERVICE BRAKES..........................................................................................................................538 CONTACTORS..............................................................................................................................539 WHEEL BEARINGS..........................................................................................................................539 Steer Wheels, Lubrication...........................................................................................................539 Drive Wheels, Lubrication ..........................................................................................................539 LIFT CHAINS.............................................................................................................................539 GENERAL PROCEDURES..........................................................................................................................540 HOW TO CHARGE THE BATTERY...............................................................................................................540 HOW TO CHANGE THE BATTERY...............................................................................................................541 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................................545 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................................546 Check the Lift Cylinders for Leaks..................................................................................................546 Check the Tilt Cylinders for Leaks..................................................................................................547 LIFT CHAIN ADJUSTMENTS..................................................................................................................547 HOW TO CHECK THE PMT CIRCUIT............................................................................................................547 WELDING REPAIRS.........................................................................................................................549 CHANGE THE OVERHEAD GUARD...............................................................................................................549 WHEELS AND TIRES............................................................................................................................549 GENERAL.................................................................................................................................549 SOLID RUBBER TIRES (PRESS-ON)...........................................................................................................550 How To Change A Solid Rubber Tire...................................................................................................550 Install The Wheels..................................................................................................................551 PNEUMATIC TIRES.........................................................................................................................551 Remove the Wheels From The Lift Truck...............................................................................................551 Remove The Tire From The Wheel .....................................................................................................551 Install The Wheel In The Tire.......................................................................................................553 Add Air To The Tires................................................................................................................554 Install The Wheels......................................................................................................................554 SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES.......................................................................................555 Remove The Tire From The Wheel......................................................................................................555 Install The Tire On The Wheel.......................................................................................................556 SPECIFICATIONS..............................................................................................................................557 REFERENCE TABLE.............................................................................................................................558 INTRODUCTION................................................................................................................................559 NOMENCLATURE, THREADS...................................................................................................................559 STRENGTH IDENTIFICATION.................................................................................................................560 TABLE 1. BOLTS AND SCREWS...................................................................................................................560 TABLE 2. STUDS AND NUTS.....................................................................................................................561 TABLE 3. TORQUE NUTS........................................................................................................................562 TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................................563 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................................564 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................................565 INTRODUCTION................................................................................................................................568 GENERAL.................................................................................................................................568 DESCRIPTION.............................................................................................................................568 REPAIRS.....................................................................................................................................569 STEERING AXLE ASSEMBLY..................................................................................................................569 Removal.............................................................................................................................569 Installation........................................................................................................................569 WHEELS..................................................................................................................................569 Removal And Disassembly.............................................................................................................569 Cleaning............................................................................................................................569 Assembly And Installation...........................................................................................................570 SPINDLES, BEARINGS, AND TIE RODS........................................................................................................570 Removal And Disassembly.............................................................................................................570 Assembly And Installation...........................................................................................................571 STEERING CYLINDER.......................................................................................................................572 Removal And Disassembly.............................................................................................................572 Cleaning And Inspection.............................................................................................................572 Assembly And Installation...........................................................................................................572 TROUBLESHOOTING.............................................................................................................................573 TORQUE SPECIFICATIONS.......................................................................................................................573 INTRODUCTION................................................................................................................................575 GENERAL.................................................................................................................................575 DESCRIPTION.............................................................................................................................575 REPAIRS.....................................................................................................................................576 STEERING AXLE ASSEMBLY..................................................................................................................576 Removal.............................................................................................................................576 Installation........................................................................................................................576 WHEEL AND HUBS..........................................................................................................................576 Removal and Disassembly.............................................................................................................576 Cleaning............................................................................................................................577 Assembly and Installation...........................................................................................................577 SPINDLES, BEARINGS AND TIE RODS.........................................................................................................578 Removal.............................................................................................................................578 Installation........................................................................................................................578 STEERING CYLINDER.......................................................................................................................578 Removal and Disassembly.............................................................................................................578 Cleaning and Inspection.............................................................................................................579 Assembly and Installation...........................................................................................................579 TORQUE SPECIFICATIONS.......................................................................................................................580 TROUBLESHOOTING.............................................................................................................................581
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]
