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Hyster E45 65XM₂, J40 65XM₂ service manual – PDF DOWNLOAD
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Description
Hyster E45 65XM₂, J40 65XM₂ service manual
File Details:
Hyster E45 65XM₂, J40 65XM₂ service manual
Language : English
Pages : 643
Size : 18.4 MB
Downloadable : Yes
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HYSTER E45 65XM₂, J40 65XM₂ SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster E45 65XM₂, J40 65XM₂ service manual
- GENERAL This section has a description and the service procedures for the parts of the brake system. The brake system includes the following parts: master cylinder, brake shoes, wheel cylinders, the parking brake system, and the seat brake system. A troubleshooting section is included at the end of this section. DESCRIPTION AND OPERATION Service Brakes (See FIGURE 1.) A service brake assembly is installed on the mounts at each end of the drive axle. The parts of the service brake assembly are shown in FIGURE 3. and FIGURE 4.
- When the brake pedal is pushed, fluid pressure from the master cylinder causes the pistons in the wheel cylinders to extend. The pistons expand the brake shoes against the drums. The clearance between the brake shoes and the brake drum is adjusted automatically. An adjuster linkage turns the adjuster wheel to adjust the clearance. When the lift truck moves in the REVERSE direction and the brakes are applied, the rear brake shoe and the adjuster links move with the drum. This linkage moves the adjuster lever to rotate the adjuster wheel.
- The adjuster wheel can turn only when there is clearance between the lining of the brake shoe and the brake drum. The adjuster wheel can also be turned with a tool. A slot in the back plate gives access to the adjuster wheel. Master Cylinder The master cylinder is designed for a dual circuit system. The master cylinder has two separate pistons that operate in the single bore of the master cylinder. The reservoir for the fluid is pressed into the two ports on top of the master cylinder and held in position by seals.
- When the brake pedal is pushed, the push rod moves the piston assemblies. The operation of the master cylinder is described in FIGURE 2. If a failure occurs in one of the dual circuits, the other circuit will apply one of the service brakes. This failure will cause the brake pedal to travel farther when the brakes are applied, but the service brakes on one drive wheel will operate. This failure of one of the brake circuits can cause the lift truck to turn toward the drive wheel with the good brake when the brakes are applied
- . The operator must control the direction of the lift truck with the steering when the brakes are applied during this condition. The reservoir is equipped with an indicator for low fluid level. A float in the reservoir moves up and down with the fluid level. When the fluid level is low, a magnet on the float activates a switch in the bottom of the reservoir. This switch energizes a warning light on the instrument cluster.
Table of Contents:
Hyster E45 65XM₂, J40 65XM₂ service manual
INTRODUCTION............................................................................................................................ 1 GENERAL............................................................................................................................. 1 DESCRIPTION AND OPERATION........................................................................................................... 1 Service Brakes.................................................................................................................. 1 Master Cylinder................................................................................................................. 1 Parking Brake................................................................................................................... 3 SERVICE BRAKES...................................................................................................................... 3 Removal And Disassembly......................................................................................................... 3 Cleaning........................................................................................................................ 5 Inspection...................................................................................................................... 6 Assembly And Installation....................................................................................................... 6 Adjustments..................................................................................................................... 8 PARKING BRAKE....................................................................................................................... 8 Removal And Disassembly......................................................................................................... 8 Assembly And Installation....................................................................................................... 9 Adjust The Parking Brake........................................................................................................ 9 MASTER CYLINDER..................................................................................................................... 12 Removal......................................................................................................................... 12 Cleaning And Inspection......................................................................................................... 12 Repair.......................................................................................................................... 12 Installation.................................................................................................................... 12 SEAT BRAKE ASSEMBLY................................................................................................................. 15 CHECKS AND ADJUSTMENTS.................................................................................................................. 16 ADJUST THE SERVICE BRAKES........................................................................................................... 16 ADJUST THE BRAKE PEDAL.............................................................................................................. 16 ADJUST THE MASTER CYLINDER.......................................................................................................... 16 REMOVE THE AIR FROM THE BRAKE SYSTEM................................................................................................ 16 TEST THE "PARKING BRAKE NOT APPLIED" WARNING........................................................................................ 16 TROUBLESHOOTING......................................................................................................................... 17 TORQUE SPECIFICATIONS................................................................................................................... 19 INTRODUCTION............................................................................................................................ 22 GENERAL............................................................................................................................. 22 DESCRIPTION AND OPERATION........................................................................................................... 22 Service Brakes.................................................................................................................. 22 Master Cylinder .................................................................................................................... 22 Parking Brake................................................................................................................... 22 SERVICE BRAKES...................................................................................................................... 24 Removal And Disassembly......................................................................................................... 24 Cleaning........................................................................................................................ 26 Inspection...................................................................................................................... 26 Assembly And Installation....................................................................................................... 27 Adjustments..................................................................................................................... 28 PARKING BRAKE....................................................................................................................... 30 Removal And Disassembly......................................................................................................... 30 Assembly And Installation ...................................................................................................... 30 Adjust The Parking Brake........................................................................................................ 31 MASTER CYLINDER..................................................................................................................... 34 Removal......................................................................................................................... 34 Cleaning And Inspection......................................................................................................... 34 Repair.......................................................................................................................... 34 Installation.................................................................................................................... 34 CHECKS AND ADJUSTMENTS.................................................................................................................. 36 ADJUST THE SERVICE BRAKES........................................................................................................... 36 ADJUST THE BRAKE PEDAL.............................................................................................................. 37 ADJUST THE MASTER CYLINDER.......................................................................................................... 37 REMOVE THE AIR FROM THE BRAKE SYSTEM................................................................................................ 37 TEST THE "PARKING BRAKE NOT APPLIED" WARNING........................................................................................ 37 TROUBLESHOOTING......................................................................................................................... 38 TORQUE SPECIFICATIONS................................................................................................................... 40 COUNTERWEIGHTS.......................................................................................................................... 41 HYDRAULIC SYSTEM........................................................................................................................ 41 WHEELS AND TIRES ....................................................................................................................... 42 BATTERY SPECIFICATIONS - E2.00-3.20XM (E45-65XM, E45-XM2, N30XMH, N30XMH2).............................................................. 42 BATTERY SPECIFICATIONS - J2.00-3.20XM (J40-65XM, J40-65XM2)............................................................................. 43 CAPACITIES.............................................................................................................................. 43 MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS............................................................................................. 43 E45-65XM MAST SPEEDS (36 or 48 Volt) Americas........................................................................................... 44 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.............................................................................. 44 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................... 45 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.............................................................................. 46 E40-65XM, E40-65XM2, N30XMH2 MAST SPEEDS (36 or 48 Volt) (3/99) Americas................................................................ 47 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*............................................................................................ 47 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*............................................................................................ 48 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe......................................................................................... 49 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.............................................................................. 49 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................... 50 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.............................................................................. 51 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe......................................................................................... 52 CONTACTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.............................................................................. 52 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.................................................................................... 53 E2.00-3.20XM, E2.00-3.20XM2, MAST SPEEDS (72 or 80 Volt) (3/99) Europe.................................................................. 54 190 mm MOTOR & LARGE LIFT PUMP*..................................................................................................... 54 190 mm MOTOR & SMALL LIFT PUMP*..................................................................................................... 55 203 or 190 mm LONG STACK MOTOR & SMALL LIFT PUMP*................................................................................... 56 J40-65XM MAST SPEEDS (36 or 48 Volt) Americas........................................................................................... 57 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.............................................................................. 57 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................... 58 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.............................................................................. 59 J40-65XM, J40-65XM2, MAST SPEEDS (36 or 48 Volt) (3/99) Americas........................................................................ 60 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*............................................................................................ 60 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*............................................................................................ 61 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe......................................................................................... 62 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................... 62 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................... 63 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................... 64 CONT. OR TRANSISTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.................................................................... 65 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.................................................................................... 66 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) (3/99) Europe.................................................................................. 67 190 mm MOTOR & LARGE LIFT PUMP*..................................................................................................... 67 190 mm MOTOR & SMALL LIFT PUMP*..................................................................................................... 68 203 or 190 mm LONG STACK MOTOR & LARGE LIFT PUMP*................................................................................... 69 TORQUE SPECIFICATIONS................................................................................................................... 70 REFERENCE TABLE......................................................................................................................... 73 INTRODUCTION............................................................................................................................ 74 ELECTRIC MOTOR MAINTENANCE, GENERAL................................................................................................. 74 BRUSH AND COMMUNICATOR INSPECTION................................................................................................... 74 Hydraulic Pump Motor And Traction Motor......................................................................................... 74 Steering Pump Motor............................................................................................................. 76 BRUSH WEAR REPLACEMENT GUIDE............................................................................................................ 76 Commutator Problems................................................................................................................. 78 BRUSH REPLACEMENTS.................................................................................................................. 80 DISASSEMBLY OF MOTORS............................................................................................................... 82 Traction Motor And Hydraulic Pump Motor......................................................................................... 82 Steering Pump Motor............................................................................................................. 88 ASSEMBLY OF MOTORS.................................................................................................................. 90 Traction Motor And Hydraulic Pump Motor ........................................................................................ 90 Steering Pump Motor............................................................................................................. 90 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS...................................................................................... 90 TESTS FOR A DAMAGED FIELD AND ARMATURE.............................................................................................. 91 Test For An Open Circuit In The Armature........................................................................................ 91 Test For A Short-Circuit In One Armature Winding................................................................................ 91 Test For A Short-Circuit To Armature Shaft...................................................................................... 92 Test For An Open Circuit In A Field Coil........................................................................................ 92 Test For A Short-Circuit In A Field Coil........................................................................................ 92 Test For A Short-Circuit Between The Field And The Motor Case................................................................... 93 Brush Holder Test............................................................................................................... 93 TROUBLESHOOTING......................................................................................................................... 93 FIGURE 1. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (E25-65XM2).................................................. 95 FIGURE 2. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (E25-65XM2)............................................................ 96 FIGURE 3. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (E25-65XM2).............................................................. 97 FIGURE 4. WIRING DIAGRAM - COMMON CONCEPTS (E25-65XM2) (SEM)............................................................................ 98 FIGURE 5. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLER (E25-65XM2)................................................................. 99 FIGURE 6. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (E25-65XM2)...................................100 FIGURE 7. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (N30XMH2)....................................................101 FIGURE 8. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (N30XMH2)..............................................................102 FIGURE 9. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (N30XMH2)................................................................103 FIGURE 10. WIRING DIAGRAM - COMMON COMPONENTS (N30XMH2).................................................................................104 FIGURE 11. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLERS (N30XMH2).................................................................105 FIGURE 12. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (N30XMH2)....................................106 FIGURE 13. ELECTRICAL WIRING CONNECTORS (E25-65XM2) (N30XMH2)...........................................................................107 FIGURE 14. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (J40-65XM2).................................................108 FIGURE 15. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (J40-65XM2)...........................................................109 FIGURE 16. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (J40-65XM2).............................................................110 FIGURE 17. WIRING DIAGRAM - COMMON COMPONENTS (J40-65XM2)...............................................................................111 FIGURE 18. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLER (J40-65XM2)................................................................112 FIGURE 19. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (J40-65XM2)..................................113 FIGURE 20. ELECTRICAL WIRING CONNECTORS (J40-65XM2).....................................................................................114 FIGURE 21. STEERING COLUMN WIRING DETAIL (E25-40XM2)....................................................................................115 FIGURE 22. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS (E25-40XM2)..............................................................116 FIGURE 23. TRUCK WIRING (E25-40XM2).....................................................................................................117 FIGURE 24. TRUCK POWER CABLES (E25-40XM2)...............................................................................................118 FIGURE 25. STEERING COLUMN WIRING DETAIL (E40-65XM2, J40-65XM2 AND N30XMH2).............................................................119 FIGURE 26. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS (E40-65XM2, J40-65XM2 AND N30XMH2).......................................120 FIGURE 27. TRUCK WIRING (E40-65XM2, J40-65XM2 AND N30XMH2)..............................................................................121 FIGURE 28. TRUCK POWER CABLES (E40-65XM2, J40-65XM2 AND N30XMH2)........................................................................122 FIGURE 29. PANEL WIRING WITH SR (SEM) AND SP MOTOR CONTROLLERS..........................................................................123 FIGURE 30. PANEL WIRING WITH SR (SEM) MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL.......................................................124 FIGURE 31. SR (SEM) AND SP MOTOR CONTROLLERS............................................................................................125 FIGURE 32. SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL OF PUMP MOTOR................................................................126 FIGURE 33. (SEM) DISPLAY PANELS.........................................................................................................127 FIGURE 34. (SEM) DISPLAY PANEL CONNECTIONS AND MOUNTING.................................................................................128 FIGURE 35. LIGHTING SCHEMATIC DIAGRAM (E25-65XM2, J40-65XM2 AND N30XMH2)................................................................129 FIGURE 36. LIGHT WIRING DIAGRAM (E25-40XM2).............................................................................................131 FIGURE 37. LIGHT WIRING DIAGRAM (E45-65XM2 AND N30XMH2).................................................................................133 INTRODUCTION............................................................................................................................136 GENERAL.............................................................................................................................136 DESCRIPTION.........................................................................................................................136 REPAIRS.................................................................................................................................138 REMOVAL OF THE DRIVE AXLE...........................................................................................................138 Disassembly of the Drive Axle...................................................................................................139 Disassembly of the Transmission and Differential................................................................................140 CLEANING............................................................................................................................142 INSPECTION..........................................................................................................................142 ASSEMBLY............................................................................................................................142 Assembly Of The Transmission And Differential...................................................................................142 Assembly Of The Drive Axle......................................................................................................148 INSTALLATION OF THE DRIVE AXLE ASSEMBLY.............................................................................................149 TROUBLESHOOTING.........................................................................................................................150 TORQUE SPECIFICATIONS...................................................................................................................151 INTRODUCTION............................................................................................................................152 GENERAL.............................................................................................................................152 DESCRIPTION.........................................................................................................................152 REPAIRS.................................................................................................................................152 REMOVAL.............................................................................................................................152 DISASSEMBLY.........................................................................................................................154 CLEANING............................................................................................................................156 INSPECTION..........................................................................................................................156 ASSEMBLY............................................................................................................................156 INSTALLATION........................................................................................................................159 TROUBLESHOOTING.........................................................................................................................160 TORQUE SPECIFICATIONS...................................................................................................................160 ELECTRICAL SYSTEM.......................................................................................................................162 GENERAL.............................................................................................................................162 "LX" SERIES DISPLAY PANEL...........................................................................................................163 Hourmeter Functions.............................................................................................................164 Battery Indicator Function......................................................................................................164 Status Code Function............................................................................................................165 "ZX" SERIES DISPLAY PANELS..........................................................................................................165 Display Panel...................................................................................................................165 Basic Display Panels............................................................................................................165 Performance Display.............................................................................................................167 Brush Wear Indicators...........................................................................................................170 SEM DISPLAY PANELS - FEATURES.......................................................................................................170 Description Of Common Features..................................................................................................171 LED SYMBOL INDICATORS...........................................................................................................171 LCD SCREEN......................................................................................................................171 BATTERY DISCHARGE INDICATOR (BDI)...............................................................................................171 SERVICE REMINDER................................................................................................................171 STATUS CODES....................................................................................................................171 HOURMETER.......................................................................................................................171 Additional Features Of Premium Display Panel ...................................................................................171 Descriptions Of Additional Features (Available With The Premium Display) .......................................................172 LCD SCREEN......................................................................................................................172 OPERATOR PASSWORDS..............................................................................................................172 DAILY CHECK LIST AND SERVICE ITEMS..............................................................................................172 PERFORMANCE MODELS..............................................................................................................172 STATUS CODE LISTS...............................................................................................................172 ADJUSTMENTS OF BDI..............................................................................................................173 SEM DISPLAY PANEL INDICATORS........................................................................................................173 All Indicator Symbols...........................................................................................................173 Hourmeter Indicator Symbol......................................................................................................174 Wrench Indicator Symbol.........................................................................................................174 Battery Indicator Symbol........................................................................................................174 Battery State-Of-Charge (BDI)...................................................................................................174 Brake Fluid Too Low Symbol......................................................................................................174 Parking Brake Symbol............................................................................................................174 Fasten Seat Belt Symbol.........................................................................................................174 LCD "Screen" (Standard Display Panel)...........................................................................................174 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM.............................................................................174 Alpha Numeric "Screen"..........................................................................................................174 "Star" Push Button..............................................................................................................175 Push Buttons #1 Through #5......................................................................................................175 OTHER CONTROL COMPONENTS............................................................................................................175 REPLACEMENT.............................................................................................................................176 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"............................................................................................176 Replace The Display Panel Assembly..............................................................................................176 Replace The Key Switch..........................................................................................................177 Indicator LEDs..................................................................................................................177 Battery Indicators..............................................................................................................177 Digital Display (Performance Display Panel Only) ...............................................................................177 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only)....................................179 Replace Parts Of The Basic Display Panel .......................................................................................179 Replace Parts Of The Performance Display Panel..................................................................................180 SEM DISPLAY PANEL...................................................................................................................181 Removal And Replacement.........................................................................................................181 REPLACE MOTOR CONTROLLER (SR or SP).................................................................................................181 OTHER CONTROL COMPONENTS............................................................................................................181 Start Swtich....................................................................................................................181 Brake Light Switch..............................................................................................................182 Seat Switch.....................................................................................................................183 Adjust The External Seat Switch.................................................................................................184 Switch For Optional Seat Brake..................................................................................................184 Parking Brake Switch............................................................................................................184 Direction Switches (Monotrol Pedal)............................................................................................185 Direction Control Switches (Steering Column)....................................................................................186 Direction Control Switches, E70-120XL3 (Steering Column)........................................................................187 Brake Fluid Switch..............................................................................................................187 Brush Wear And Over Temperature Sensors.........................................................................................187 Rocker Switches For Lights .....................................................................................................188 Accelerator Position Sensor.....................................................................................................188 On-Demand Steering Components...................................................................................................190 Lights, Converter, Relay And Reverse Alarm......................................................................................192 Horn And Horn Buttons...........................................................................................................195 Hydraulic Pump Switches.........................................................................................................196 CHECKS AND ADJUSTMENTS..................................................................................................................196 GENERAL.............................................................................................................................196 CONTROL AND POWER FUSES - "LX" OR "ZX"..............................................................................................196 CONTROL AND POWER FUSES - SEM.......................................................................................................199 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"........................................................................202 THERMAL SENSORS - SEM...............................................................................................................202 ADJUST THE START SWITCH.............................................................................................................202 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3...............................................................203 Direction Switches (MONOTROL)...................................................................................................205 ADJUST THE BRAKE LIGHT SWITCH...................................................................................................205 CHECK SEAT SWITCH...............................................................................................................205 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE.......................................................................................205 ADJUST THE PARKING BRAKE SWITCH.................................................................................................206 DIRECTIONAL SWITCHES............................................................................................................206 DIRECTIONAL SWITCHES (STEERING COLUMN)..........................................................................................206 HYDRAULIC PUMP SWITCHES.........................................................................................................206 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT..................................................................................206 ADJUST THE ACCELERATOR POSITION SENSOR..........................................................................................207 INTRODUCTION............................................................................................................................209 GENERAL.............................................................................................................................209 DESCRIPTION.........................................................................................................................209 Main Frame......................................................................................................................209 Other Frame Weldments...........................................................................................................209 Battery Restraint/Hood Frame And Plate For Optional Seat Brake..................................................................211 Overhead Guard..................................................................................................................212 REPAIRS.................................................................................................................................213 OVERHEAD GUARD......................................................................................................................213 Removal.........................................................................................................................213 Installation....................................................................................................................213 BATTERY RESTRAINT AND SEAT ASSEMBLY.................................................................................................213 COUNTERWEIGHT.......................................................................................................................214 Removal.........................................................................................................................214 Installation....................................................................................................................215 TRACTION MOTOR......................................................................................................................215 Removal.........................................................................................................................215 Installation....................................................................................................................217 HYDRAULIC TANK......................................................................................................................217 Inspection......................................................................................................................217 Repairs, Small Leaks............................................................................................................217 Repairs, Large Leaks............................................................................................................218 Cleaning........................................................................................................................218 Steam Method Of Cleaning........................................................................................................218 Chemical Solution Method Of Cleaning............................................................................................218 Additional Preparations For Repair..............................................................................................219 PAINTING INSTRUCTIONS...............................................................................................................220 LABEL REPLACEMENT...................................................................................................................221 INTRODUCTION............................................................................................................................223 GENERAL ............................................................................................................................223 DESCRIPTION.........................................................................................................................223 Main Frame......................................................................................................................223 Other Frame Weldments...........................................................................................................223 Battery Restraint/Hood Frame....................................................................................................223 Overhead Guard..................................................................................................................229 REPAIRS.................................................................................................................................229 OVERHEAD GUARD......................................................................................................................229 Removal.........................................................................................................................229 Installation....................................................................................................................229 BATTERY RESTRAINT AND SEAT ASSEMBLY.................................................................................................229 Removal.........................................................................................................................229 COUNTERWEIGHT.......................................................................................................................230 Counterweight Removal...........................................................................................................230 Counterweight Installation......................................................................................................231 TRACTION MOTOR......................................................................................................................231 Motor Removal...................................................................................................................231 Motor Installation..............................................................................................................232 HYDRAULIC TANK......................................................................................................................233 Tank Removal....................................................................................................................233 Tank Inspection.................................................................................................................233 Tank Repairs, Small Leaks.......................................................................................................233 Tank Repairs, Large Leaks.......................................................................................................233 Tank Cleaning...................................................................................................................234 Steam Method Of Cleaning Tank...................................................................................................234 Chemical Solution Method Of Cleaning Tank.......................................................................................234 Additional Preparations For Tank Repair.........................................................................................234 Tank Installation (See FIGURE 10.)..............................................................................................235 PAINTING INSTRUCTIONS...............................................................................................................236 LABEL REPLACEMENT...................................................................................................................236 INTRODUCTION............................................................................................................................240 GENERAL.............................................................................................................................240 DESCRIPTION AND OPERATION...........................................................................................................240 Carriages.......................................................................................................................240 Mast Mounts.....................................................................................................................241 TWO-STAGE MAST, LIMITED FREE-LIFT...................................................................................................242 Description and Operation.......................................................................................................242 TWO-STAGE MAST, FULL FREE-LIFT......................................................................................................244 Description.....................................................................................................................244 Operation.......................................................................................................................244 THREE-STAGE, FULL FREE-LIFT MAST....................................................................................................246 Description.....................................................................................................................246 Operation.......................................................................................................................246 INTRODUCTION ...........................................................................................................................248 GENERAL ............................................................................................................................248 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ...........................................................................................248 REPAIRS ................................................................................................................................249 FORKS ..............................................................................................................................249 Removal ........................................................................................................................249 Installation ...................................................................................................................250 CARRIAGES ..........................................................................................................................250 Removal, Standard Carriage .....................................................................................................250 Removal, Side–Shift Carriage ...................................................................................................251 Repairs ........................................................................................................................251 Installation, Standard Carriage ................................................................................................251 Installation, Side–Shift Carriage ..............................................................................................252 MAST ...............................................................................................................................253 Removal ........................................................................................................................253 Disassembly, Three–Stage FFL Mast ..............................................................................................259 Disassembly, Two–Stage LFL And Two–Stage FFL Masts .............................................................................253 Cleaning and Inspection ........................................................................................................259 Assembly, Two–Stage LFL And Two–Stage FFL Mast .................................................................................262 Assembly, Three–Stage FFL Mast .................................................................................................263 Installation, Mast .............................................................................................................264 LIFT CYLINDERS .....................................................................................................................265 Removal, Main Lift Cylinders ...................................................................................................265 Removal, Free–Lift Cylinder ....................................................................................................265 Disassembly, Lift Cylinders ....................................................................................................265 Assembly, Lift Cylinders .......................................................................................................266 Installation, Main Lift Cylinders ..............................................................................................267 Installation, Free–Lift Cylinder ...............................................................................................268 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) .......................................269 New Hose Installation, Two–Stage, LFL Mast .....................................................................................269 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .....................................................................269 New Hose Installation, Two–Stage FFL Mast ......................................................................................273 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .....................................................................273 New Hose Installation, Three–Stage FFL Mast ....................................................................................277 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ..................................................................282 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) .......................284 New Hose Installation, Two–Stage LFL Mast ......................................................................................285 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .....................................................................285 New Hose Installation, Two–Stage FFL Mast ......................................................................................288 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .....................................................................288 New Hose Installation, Three–Stage, FFL Mast ...................................................................................292 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ..................................................................297 CHECKS AND ADJUSTMENTS .................................................................................................................298 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM .......................................................................................298 Check The Lift Cylinders For Leaks ............................................................................................298 Check The Tilt Cylinders For Leaks ............................................................................................298 ADJUST THE TILT CYLINDERS .........................................................................................................298 ADJUST THE LIFT CHAINS ............................................................................................................299 ADJUST THE MAST ...................................................................................................................300 ADJUST THE CARRIAGE ...............................................................................................................301 TROUBLESHOOTING.........................................................................................................................302 INTRODUCTION............................................................................................................................303 GENERAL.............................................................................................................................303 DESCRIPTION.........................................................................................................................304 Hydraulic System................................................................................................................304 OPERATION...........................................................................................................................304 Hydraulic System................................................................................................................304 Hydraulic Gear Pump.............................................................................................................305 Rotator Actuator Valve..........................................................................................................305 Steering Pump...................................................................................................................308 REPAIRS.................................................................................................................................312 HYDRAULIC TANK......................................................................................................................312 E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal.................................................................................312 J2.00-3.20XM (J40-65XM) Tank Removal............................................................................................312 Tank Inspection.................................................................................................................312 Tank Repairs, Small Leaks.......................................................................................................313 Tank Repairs, Large Leaks ......................................................................................................313 Tank Cleaning...................................................................................................................313 Steam Method Of Cleaning Tank...................................................................................................313 Chemical Solution Method Of Cleaning Tank.......................................................................................313 Additional Preparations For Tank repair.........................................................................................314 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation............................................................................314 J2.00-3.20XM (J40-65XM) Tank Installation.......................................................................................314 FILTER REPLACEMENT..................................................................................................................315 HYDRAULIC PUMP......................................................................................................................315 Removing E1.50-3.20XM (E25-65XM) and N30XMH Hydraulic Pump......................................................................315 Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump...............................................................................316 Pump Seal Replacement And Pump Assembly.........................................................................................316 Assemble Pump On The Motor......................................................................................................318 Install The Hydraulic Pump And Motor Assembly [E1.50-3.20XM (E25-65XM) and N30XMH]..............................................319 Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly...............................................................319 MAIN CONTROL VALVE..................................................................................................................320 STEERING PUMP.......................................................................................................................320 Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N30XMH................................................................320 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM)...........................................................................321 Pump Assembly And Installation..................................................................................................322 ROTARY ACTUATOR VALVE...............................................................................................................323 Disassembly, Cleaning and Inspection............................................................................................323 Assembly........................................................................................................................323 STEERING CONTROL UNIT...............................................................................................................323 Control Unit Removal............................................................................................................324 Control Unit Installation.......................................................................................................324 STEERING CYLINDER...................................................................................................................324 CHECKS AND ADJUSTMENTS..................................................................................................................326 MAIN CONTROL VALVE..................................................................................................................326 STEERING RELIEF VALVE...............................................................................................................326 TROUBLESHOOTING CHART...................................................................................................................326 SPECIFICATIONS..........................................................................................................................330 INTRODUCTION............................................................................................................................333 GENERAL.............................................................................................................................333 LEAD-ACID BATTERIES.................................................................................................................333 SPECIFIC GRAVITY....................................................................................................................334 CHEMICAL REACTION IN A CELL.........................................................................................................334 ELECTRICAL TERMS....................................................................................................................335 HOW TO SELECT THE BATTERY...........................................................................................................335 VOLTAGE OF A BATTERY................................................................................................................335 THE BATTERY AS A COUNTERWEIGHT......................................................................................................336 BATTERY RATINGS.....................................................................................................................336 Kilowatt-Hours..................................................................................................................337 BATTERY MAINTENANCE.....................................................................................................................337 SAFETY PROCEDURES...................................................................................................................337 MAINTENCE RECORDS...................................................................................................................338 THE NEW BATTERY.....................................................................................................................338 HOW TO CLEAN THE BATTERY............................................................................................................339 HOW TO ADD WATER....................................................................................................................339 THE HYDROMETER......................................................................................................................340 BATTERY TEMPERATURE.................................................................................................................340 CHARGING THE BATTERY................................................................................................................341 Types Of Battery Charges........................................................................................................342 Methods Of Charging.............................................................................................................343 Troubleshooting The Charger.....................................................................................................343 How to Know When The Battery Is Fully Charged...................................................................................344 WHERE TO CHARGE THE BATTERIES.......................................................................................................344 Equipment Needed................................................................................................................344 BATTERY CONNECTORS..................................................................................................................345 BATTERY CARE........................................................................................................................345 INTRODUCTION............................................................................................................................347 GENERAL.............................................................................................................................347 DESCRIPTION.........................................................................................................................347 REPAIRS.................................................................................................................................351 REMOVAL AND DISASSEMBLY.............................................................................................................351 ASSEMBLY AND INSTALLATION...........................................................................................................351 INTRODUCTION............................................................................................................................354 GENERAL.............................................................................................................................354 DESCRIPTION.........................................................................................................................354 OPERATION...........................................................................................................................355 E1.50-3.20XM (E25-65XM).........................................................................................................356 J2.00-3.20XM (J40-65XM).........................................................................................................356 Lift Section....................................................................................................................356 Tilt Section....................................................................................................................357 Relief Valve....................................................................................................................359 REPAIRS.................................................................................................................................360 MAIN CONTROL VALVE..................................................................................................................360 Removal.........................................................................................................................360 Disassembly.....................................................................................................................360 Cleaning And Inspection.........................................................................................................360 Assembly........................................................................................................................360 Installation, E1.50-3.20XM (E25-65XM)...........................................................................................362 Installation, J2.00-3.20XM (J40-65XM)...........................................................................................364 CONTROL LEVER LINKAGE, E1.50-3.20XM (E25-65XM)......................................................................................365 Removal.........................................................................................................................365 Disassembly.....................................................................................................................366 Assembly And Installation.......................................................................................................366 CONTROL VALVE LINKAGE, E1.50-3.20XM (E25-65XM)......................................................................................366 Removal And Disassembly.........................................................................................................366 Assembly And Installation.......................................................................................................367 CONTROL LEVER LINKAGE, J2.00-3.20XM (J40-65XM)......................................................................................367 Removal.........................................................................................................................367 Disassembly.....................................................................................................................367 Assembly And Installation.......................................................................................................369 CHECKS AND ADJUSTMENTS..................................................................................................................370 PRESSURE RELIEF VALVES..............................................................................................................370 Primary Relief Valve............................................................................................................370 Secondary Relief Valve..........................................................................................................370 TROUBLESHOOTING.........................................................................................................................371 INTRODUCTION............................................................................................................................373 GENERAL.............................................................................................................................373 SERIAL NUMBER DATA..................................................................................................................373 HOW TO MOVE A DISABLED LIFT TRUCK...................................................................................................373 How To Tow A Lift Truck ........................................................................................................373 HOW TO PUT A LIFT TRUCK ON BLOCKS...................................................................................................374 How To Raise The Drive Tires....................................................................................................374 How To Raise The Steering Tires.................................................................................................374 MAINTENANCE SCHEDULE....................................................................................................................375 MAINTENANCE PROCEDURES..................................................................................................................378 EVERY 8 HOURS OR DAILY..................................................................................................................378 Tires And Wheels....................................................................................................................378 Forks...............................................................................................................................379 Fork Adjustment.....................................................................................................................379 Fork Removal........................................................................................................................379 Fork Installation...................................................................................................................380 Inspection Of Forks, Mast And Lift Chains...........................................................................................380 Safety Labels.......................................................................................................................381 Steering Column Latch...............................................................................................................381 Operator Restraint System...........................................................................................................382 Battery Restraint System, E25-65XM, E25-65XM2......................................................................................382 Battery Restraint System - J40-65XM-65XM, J40-65XM2................................................................................383 Battery.............................................................................................................................383 Hydraulic System....................................................................................................................384 HOW TO MAKE CHECKS WITH THE KEY "ON"................................................................................................385 Gauges, Horn And Fuses..........................................................................................................385 Steering System.................................................................................................................385 Service Brake...................................................................................................................385 Parking Brake...................................................................................................................386 Control Levers And Pedals.......................................................................................................386 Lift System Operation...........................................................................................................386 EVERY 350 HOURS OR THREE MONTHS ........................................................................................................387 HYDRAULIC TANK BREATHER.............................................................................................................387 DIFFERENTIAL AND SPEED REDUCER......................................................................................................387 WHEEL NUT TORQUES...................................................................................................................388 STEERING AXLE SPINDLES..............................................................................................................388 MAST................................................................................................................................388 LIFT CHAINS.........................................................................................................................389 Check For Wear..................................................................................................................389 Lubrication.....................................................................................................................389 FORKS...............................................................................................................................389 BRAKE FLUID.........................................................................................................................390 OTHER LUBRICATION...................................................................................................................390 SEAT BRAKE (E25-65XM, E25-65XM2 Only................................................................................................390 ELECTRICAL INSPECTION...............................................................................................................390 Contactors......................................................................................................................391 Motor Brushes...................................................................................................................391 Motor Brushes, General..........................................................................................................391 EVERY 2000 HOURS OR YEARLY..............................................................................................................401 HYDRAULIC SYSTEM....................................................................................................................401 Change The Filter For The Hydraulic Oil.........................................................................................401 Change The Hydraulic Oil........................................................................................................402 DIFFERENTIAL AND SPEED REDUCER......................................................................................................402 SERVICE BRAKES......................................................................................................................402 CONTACTORS..........................................................................................................................403 WHEEL BEARINGS......................................................................................................................403 Steer Wheels, Lubrication.......................................................................................................403 Drive Wheels, Lubrication.......................................................................................................403 LIFT CHAINS.........................................................................................................................403 GENERAL PROCEDURE.......................................................................................................................403 HOW TO CHARGE THE BATTERY...........................................................................................................403 HOW TO CHANGE THE BATTERY...........................................................................................................405 General.........................................................................................................................405 Change The E25-65XM, E25-65XM2 Battery..........................................................................................405 Change The J40-65XM, J40-65XM2 Battery..........................................................................................407 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.........................................................................................409 Check The Lift Cylinders For Leaks..............................................................................................409 Check The Tilt Cylinders For Leaks..............................................................................................409 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)...............................................................................410 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)...............................................................................411 LIFT CHAIN ADJUSTMENTS..............................................................................................................411 HOW TO CHECK THE PMT CIRCUIT........................................................................................................412 WELDING REPAIRS.....................................................................................................................413 CHANGES TO THE OVERHEAD GUARD.......................................................................................................413 TIRES AND WHEELS, E25-65XM, E25-65XM2...............................................................................................413 Remove The Wheels From The Lift Truck..........................................................................................414 Remove And Install The Tire On The Wheel........................................................................................414 PNEUMATIC TIRES AND WHEELS J40-65XM, J40-65XM2......................................................................................414 Remove The Wheels From The Lift Truck...........................................................................................414 Remove The Wheel From The Pneumatic Tire........................................................................................415 Install The Wheel In The Pneumatic Tire.........................................................................................416 Add Air To The Tires............................................................................................................417 Install The Wheels..............................................................................................................417 SOLID RUBBER TIRES ON PNEUMATIC WHEELS..............................................................................................417 Remove The Wheels From The Lift Truck...........................................................................................417 Remove The Solid Rubber Tire From The Pneumatic Wheel...........................................................................417 Install The Solid Rubber Tire On The Pneumatic Wheel............................................................................419 Install The Wheels .............................................................................................................419 REFERENCE TABLE.........................................................................................................................420 Adhesive And Sealants ..............................................................................................................420 INTRODUCTION............................................................................................................................421 NOMENCLATURE, THREADS...............................................................................................................421 STRENGTH IDENTIFICATION.............................................................................................................422 TABLE 1. BOLTS AND SCREWS...............................................................................................................422 TABLE 2. STUDS AND NUTS.................................................................................................................423 TABLE 3. TORQUE NUTS....................................................................................................................424 TABLE 4. TORQUE NUTS WITH NYLON INSERT..................................................................................................425 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...............................................................................................426 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.............................................................................................427 SEM DISPLAY PANEL.......................................................................................................................430 GENERAL.............................................................................................................................430 SEM DISPLAY PANEL FEATURES..........................................................................................................430 Description Of Common Features..................................................................................................430 LED SYMBOL INDICATORS...........................................................................................................430 LED SCREEN .....................................................................................................................430 BATTERY DISCHARGE INDICATOR (BDI)...............................................................................................430 SERVCE REMINDER.................................................................................................................431 STATUS CODES....................................................................................................................431 HOURMETER.......................................................................................................................431 Additional Features Of Premium Display Panel....................................................................................431 Descriptions Of Additional Features (Available With The Premium Display)........................................................431 LCD SCREEN......................................................................................................................431 OPERATOR PASSWORDS..............................................................................................................431 DAILY CHECK LIST AND SERVICE ITEMS..............................................................................................432 PERFORMANCE MODES...............................................................................................................432 STATUS CODES LIST...............................................................................................................432 ADJUSTMENT OF BDI...............................................................................................................433 SEM DISPLAY PANEL INDICATORS........................................................................................................433 All Indicator Symbols...........................................................................................................433 Hourmeter Indicator Symbol......................................................................................................434 Wrench Indicator Symbol.........................................................................................................434 Battery Indicator Symbol........................................................................................................434 Battery State-Of-Charge (BDI)...................................................................................................434 Brake Fluid Too Low Symbol......................................................................................................434 Parking Brake Symbol............................................................................................................434 Fasten Seat Belt Symbol.........................................................................................................434 LCD Screen (Standard Display Panel).............................................................................................434 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL..................................................................................434 Alpha Numeric Screen............................................................................................................434 "STAR" Push Button..............................................................................................................435 Push Buttons #1 Through #5......................................................................................................435 ADJUSTMENTS WITH A COMPUTER.........................................................................................................436 COMPUTER SYSTEM.................................................................................................................436 Connect A PC To The SEM Display Panel...........................................................................................436 ITW SWITCHES SOFTWARE PROGRAM (For SEM Display Panel)...........................................................................437 Description.................................................................................................................437 Where To Get Help...........................................................................................................437 Hardware And Software Requirements..........................................................................................437 How To Start The ITW SWITCHES Program.......................................................................................438 Menus.......................................................................................................................438 Create A Setup File.........................................................................................................446 REPLACEMENT.........................................................................................................................466 GENERAL.........................................................................................................................466 SEM DISPLAY PANEL...............................................................................................................466 Removal And Replacement ........................................................................................................466 TRANSISTOR MOTOR CONTROLLERS (SR AND SP) DESCRIPTION, CHECKS & ADJUSTMENTS, TROUBLESHOOTING, REPAIRS, AND THEORY OF OPERATION...........469 DESCRIPTION.........................................................................................................................469 General.........................................................................................................................469 Model Number Data For Transistor Motor Controllers (SR and SP)..................................................................470 MOTOR CONTROLLER, CHECKS AND ADJUSTMENTS............................................................................................472 CHECKS AND ADJUSTMENTS USING A HAND SET.............................................................................................473 General.........................................................................................................................473 Connect Hand Set................................................................................................................474 Start Sequence..................................................................................................................474 Check Or Delete Stored Status Codes.............................................................................................474 Returning The Lift Truck To Normal Operation....................................................................................475 Checks And Adustments On The Work Bench.........................................................................................475 How To Check And Adjust The Registers...........................................................................................477 ADJUSTMENTS - FUNCTION PARAMETERS...................................................................................................478 General.........................................................................................................................478 Function Numbers................................................................................................................478 When The Hand Set Is Connected To A Motor Controller In The Lift Truck..........................................................479 FUNCTION NUMBER DESCRIPTIONS........................................................................................................480 TRACTION MOTOR CONTROLLER (LABEL LETTER - SR).......................................................................................480 FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY...........................................................................................485 PUMP MOTOR CONTROLLER (LABEL LETTER - SP)...........................................................................................487 FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY...........................................................................................490 TROUBLESHOOTING - STATUS CODE CHARTS....................................................................................................495 TROUBLESHOOTING.....................................................................................................................496 General.........................................................................................................................496 Status Codes....................................................................................................................496 REPAIRS.................................................................................................................................524 GENERAL.............................................................................................................................524 GENERAL MAINTENANCE INSTRUCTIONS....................................................................................................524 Special Precautions.............................................................................................................524 FUSES...............................................................................................................................527 CONTACTORS..........................................................................................................................527 Contactor Repair................................................................................................................527 CONTACTOR DRIVER MODULE.............................................................................................................529 Replace Contactor Driver........................................................................................................529 MOTOR CONTROLLER PLUG...............................................................................................................529 BRUSH WEAR INDICATORS...............................................................................................................529 THERMAL SENSORS.....................................................................................................................530 REPLACE MOTOR CONTROLLER............................................................................................................530 THEORY OF OPERATION.....................................................................................................................535 GENERAL.............................................................................................................................535 DESCRIPTION OF SEM SYSTEM...........................................................................................................535 OPERATION OF SEM SYSTEM (SR MOTOR CONTROLLER).......................................................................................536 Reverse Circuit.................................................................................................................536 Performance and Efficiency......................................................................................................536 Field Weakening.................................................................................................................537 Regenerative Braking............................................................................................................537 INTRODUCTION........................................................................................................................537 General.........................................................................................................................537 Creep Speed.....................................................................................................................537 Controlled Acceleration.........................................................................................................537 Current Limit...................................................................................................................538 BRAKING.............................................................................................................................538 Regenerative Braking to Zero Speed..............................................................................................538 Pedal Position Braking..........................................................................................................538 Auto Braking....................................................................................................................538 AUXILIARY SPEED CONTROL.............................................................................................................538 Field Weakening.................................................................................................................538 Speed Limits....................................................................................................................539 RAMP OPERATION......................................................................................................................539 Ramp Start......................................................................................................................539 Anti-Rollback...................................................................................................................539 STEER PUMP CONTACTOR TIME DELAY.....................................................................................................539 COIL DRIVERS AND INTERNAL COIL SUPPRESSION..........................................................................................539 SYSTEM PROTECTIVE OVERRIDE..........................................................................................................539 SRO (Static Return to Off)......................................................................................................539 Accelerator Volts Hold Off......................................................................................................539 Pulse Monitor Trip (PMT)........................................................................................................539 Thermal Protector (TP)..........................................................................................................540 Low Voltage.....................................................................................................................540 SP PUMP MOTOR CONTROLLERS...........................................................................................................540 CONTACTOR DRIVER MODULE.............................................................................................................540 DIAGNOSTICS.........................................................................................................................541 System Diagnostics..............................................................................................................541 Standard Status Codes...........................................................................................................541 Stored Status Codes.............................................................................................................541 Hourmeter Readings..............................................................................................................541 Maintenance Management Capability...............................................................................................541 SR (SEM) AND SP TRANSISTOR MOTOR CONTROLLER,Parameter Tables............................................................................547 GENERAL.............................................................................................................................547 Function Numbers...............................................................................................................547 MOTOR CONTROLLER CHECKS AND ADJUSTMENTS.............................................................................................548 TABLE 1.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V) (Standard Speed Motor With EE ....549 Parameter Tables................................................................................................................548 TABLE 2.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V) (High Speed Motor With E or ES....551 TABLE 3.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V).............................................553 TABLE 4.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E45-65XM2 (F108) (36 to 48V) (9 Inch Traction Motor)...........555 TABLE 5.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E45-65XM2 (F108) (36 to 48V) (11 Inch Traction Motor)..........558 TABLE 6.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER -E45-65XM2 (F108) (36 to 48V)..............................................561 TABLE 7.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER -J45-65XM2 (A216) (36 to 48V) (E OR ES RATED)....................563 TABLE 8.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER -J45-65XM2 (A216) (36 to 48V) (EE RATED).........................565 TABLE 9.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - J45-65XM2 (A216) (36 to 48V).............................................567 TABLE 10.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V) (9 INCH MOTOR).....................569 TABLE 11.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V) (11 INCH MOTOR)....................572 TABLE 12.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V)..............................................575 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers................................577 COMPUTER SYSTEM.....................................................................................................................577 Connect A PC To A Control Card..................................................................................................578 HYTECt SOFTWARE PROGRAM ............................................................................................................579 How To Start The Program........................................................................................................579 Selecting The Communications Port...............................................................................................580 Verification Of Controller and Lift Truck.......................................................................................580 Select The Lift Truck Series....................................................................................................581 Undefined Controller Card.......................................................................................................582 Controller Card Register Parameter List.........................................................................................582 How To Enter A New Parameter....................................................................................................583 How To Save A Changed Parameter File............................................................................................584 How To Load A Saved Parameter File..............................................................................................584 How To Return To Factory Default Settings.......................................................................................585 How To Save Changes To The Controller Card......................................................................................586 How To View The Status Codes ...................................................................................................586 Saving The Status Code To Disk..................................................................................................587 Closing and Clearing The Status Code List.......................................................................................588 COMMUNICATIONS PROGRAM (MODEM)......................................................................................................588 Requirements....................................................................................................................589 README File.....................................................................................................................590 GE Sentry Software..................................................................................................................590 Getting Started.................................................................................................................590 Where To Get Help...............................................................................................................591 Hardware and Software Requirements..............................................................................................591 Installation of the GE SENTRY SOFTWARE..........................................................................................591 How To Start The GE SENTRY Program..............................................................................................591 How To Reset The MIN and MAX Display............................................................................................593 How To Exit The GE SENTRY Program...............................................................................................593 INTRODUCTION............................................................................................................................594 GENERAL.............................................................................................................................594 DESCRIPTION.........................................................................................................................594 REPAIRS.................................................................................................................................595 STEERING AXLE ASSEMBLY..............................................................................................................595 Removal.........................................................................................................................595 Installation....................................................................................................................595 WHEELS..............................................................................................................................595 Removal And Disassembly.........................................................................................................595 Cleaning........................................................................................................................595 Assembly And Installation.......................................................................................................596 SPINDLES, BEARINGS, AND TIE RODS....................................................................................................596 Removal And Disassembly.........................................................................................................596 Assembly And Installation.......................................................................................................597 STEERING CYLINDER...................................................................................................................598 Removal And Disassembly.........................................................................................................598 Cleaning And Inspection.........................................................................................................598 Assembly And Installation.......................................................................................................598 TROUBLESHOOTING.........................................................................................................................599 TORQUE SPECIFICATIONS...................................................................................................................599 STEERING SYSTEM.........................................................................................................................601 GENERAL.............................................................................................................................601 DESCRIPTION.........................................................................................................................603 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................................................604 Removal Of The Assembly Components..............................................................................................604 Installation Of The Assembly Components.........................................................................................608 POWER STEERING MOTOR AND PUMP...........................................................................................................609 DESCRIPTION.........................................................................................................................609 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)..................................609 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3).......................................................................609 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)....................................................................................610 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)...................................................................................612 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)..................................................................................613 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]......................................613 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)..................................................................................614 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)................................................................................616 REPAIRS, POWER STEERING PUMP........................................................................................................617 Seal Replacement................................................................................................................618 HYDRAULIC STEERING MOTOR................................................................................................................618 DESCRIPTION.........................................................................................................................618 REPAIRS, HYDRAULIC STEERING MOTOR...................................................................................................619 Removal ........................................................................................................................619 Disassembly.....................................................................................................................619 Cleaning And Inspection.........................................................................................................619 Assembly........................................................................................................................620 Installation, Hydraulic Steering Motor..........................................................................................621 CHECKS AND ADJUSTMENTS..................................................................................................................621 AIR IN THE STEERING SYSTEM..........................................................................................................621 CHECK STEERING PRESSURE.............................................................................................................621 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only).......................................................................622 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS.......................................................................................623 TROUBLESHOOTING.........................................................................................................................625 INTRODUCTION............................................................................................................................628 GENERAL.............................................................................................................................628 DESCRIPTION.........................................................................................................................628 OPERATION...........................................................................................................................628 REPAIRS.................................................................................................................................629 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................................................629 Removal of the Assembly Components..............................................................................................633 Disassembly of the Steering Control Unit........................................................................................634 Cleaning of the Steering Control Unit...........................................................................................634 Assembly of the Steering Control Unit...........................................................................................634 Installation of the Steering Control Unit.......................................................................................634 Installation of the Assembly Components.........................................................................................634 CHECKS AND ADJUSTMENTS..................................................................................................................642 REMOVE AIR FROM THE SYSTEM..........................................................................................................642 TROUBLESHOOTING.........................................................................................................................642
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Tate M –
It was ok all i want is the manual that I paid for