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Hyster E45 65XM service manual – PDF DOWNLOAD
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Description
Hyster E45 65XM service manual
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Hyster E45 65XM service manual
Language : English
Pages : 647
Size : 20.00 MB
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HYSTER E45 65XM SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster E45 65XM service manual
- 1 INTRODUCTION GENERAL This section has the description and repair procedures for the Four–Stage, full free–lift (FFL) mast and the carriages. Checks and Adjustments and Troubleshooting information are at the end of this section. The mast is used to lift a load vertically.
- The mast has two movements controlled by hydraulic cylinders: forward and backward tilt and the lifting and lowering of the mast weldments and carriage. The outer weldment can move on the pivot pins at the mast mounts. The operation of the tilt cylinders causes the mast to tilt forward and backward. The tilt cylinders are fastened between the frame of the lift truck and the outer weldment of the mast. Hydraulic lift cylinders are installed vertically on the mast weldments.
- The lift cylinders and lift chains raise and lower the weldments and the carriage. The hydraulic operation of the lift cylinders and tilt cylinders is described in the section MAIN CONTROL VALVE. CARRIAGES (See FIGURE 1.) The carriage is a part of the mast assembly and moves within the channels of the inner weldment. Forks or other types of load handling equipment are attached to the carriage. A load backrest extension is attached to the carriage and adds support for a load that has multiple pieces.
- The side–shift carriage lets the operator move the forks and load from side–to–side. This function makes it easier for the operator to align the forks with a load or align the load with a stack. The side–shift carriage hangs on the fork bars of the standard carriage. Special bushings fit between the side–shift carriage and the fork bars. A side–shift cylinder is installed on a bracket that fits on the standard carriage. The side–shift cylinder moves the side–shift carriage on the standard carriage.
Table of Contents:
Hyster E45 65XM service manual
INTRODUCTION................................................................................................................................ 1 GENERAL................................................................................................................................. 1 CARRIAGES............................................................................................................................... 1 MAST MOUNTS............................................................................................................................. 2 MAST.................................................................................................................................... 2 Description......................................................................................................................... 2 Operation........................................................................................................................... 3 REPAIRS..................................................................................................................................... 6 FORKS................................................................................................................................... 6 Removal............................................................................................................................. 6 Installation........................................................................................................................ 6 SAFETY PROCEUDRES WHEN WORKING NEAR THE MAST............................................................................................ 7 CARRIAGES............................................................................................................................... 8 Removal............................................................................................................................. 8 Repairs............................................................................................................................. 9 Installation........................................................................................................................ 9 MAST.................................................................................................................................... 10 Removal............................................................................................................................. 10 Disassembly......................................................................................................................... 10 Cleaning and Inspection............................................................................................................. 12 Assembly............................................................................................................................ 15 Installation........................................................................................................................ 16 LIFT CYLINDERS.......................................................................................................................... 16 Removal............................................................................................................................. 16 Disassembly......................................................................................................................... 17 Assembly............................................................................................................................ 17 Installation........................................................................................................................ 18 HEADER HOSE ARRANGEMENTS................................................................................................................ 20 Installation, Header Hoses.......................................................................................................... 20 CHECKS AND ADJUSTMENTS...................................................................................................................... 26 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM............................................................................................. 26 Check The Lift Cylinders For Leaks.................................................................................................. 26 Check The Tilt Cylinders For Leaks.................................................................................................. 27 ADJUST THE TILT CYLINDERS............................................................................................................... 27 LIFT CHAIN ADJUSTMENTS.................................................................................................................. 27 MAST ADJUSTMENTS........................................................................................................................ 28 CARRIAGE ADJUSTMENTS.................................................................................................................... 29 TROUBLESHOOTING............................................................................................................................. 31 INTRODUCTION................................................................................................................................ 32 GENERAL................................................................................................................................. 32 DESCRIPTION AND OPERATION............................................................................................................... 32 Service Brakes...................................................................................................................... 32 Master Cylinder..................................................................................................................... 32 Parking Brake....................................................................................................................... 34 SERVICE BRAKES.......................................................................................................................... 34 Removal And Disassembly............................................................................................................. 34 Cleaning............................................................................................................................ 36 Inspection.......................................................................................................................... 37 Assembly And Installation........................................................................................................... 37 Adjustments......................................................................................................................... 39 PARKING BRAKE........................................................................................................................... 39 Removal And Disassembly............................................................................................................. 39 Assembly And Installation........................................................................................................... 40 Adjust The Parking Brake............................................................................................................ 40 MASTER CYLINDER......................................................................................................................... 43 Removal............................................................................................................................. 43 Cleaning And Inspection............................................................................................................. 43 Repair.............................................................................................................................. 43 Installation........................................................................................................................ 43 SEAT BRAKE ASSEMBLY..................................................................................................................... 46 CHECKS AND ADJUSTMENTS...................................................................................................................... 47 ADJUST THE SERVICE BRAKES............................................................................................................... 47 ADJUST THE BRAKE PEDAL.................................................................................................................. 47 ADJUST THE MASTER CYLINDER.............................................................................................................. 47 REMOVE THE AIR FROM THE BRAKE SYSTEM.................................................................................................... 47 TEST THE "PARKING BRAKE NOT APPLIED" WARNING............................................................................................ 47 TROUBLESHOOTING............................................................................................................................. 48 TORQUE SPECIFICATIONS....................................................................................................................... 50 INTRODUCTION................................................................................................................................ 53 GENERAL................................................................................................................................. 53 DESCRIPTION AND OPERATION............................................................................................................... 53 Service Brakes...................................................................................................................... 53 Master Cylinder ........................................................................................................................ 53 Parking Brake....................................................................................................................... 53 SERVICE BRAKES.......................................................................................................................... 55 Removal And Disassembly............................................................................................................. 55 Cleaning............................................................................................................................ 57 Inspection.......................................................................................................................... 57 Assembly And Installation........................................................................................................... 58 Adjustments......................................................................................................................... 59 PARKING BRAKE........................................................................................................................... 61 Removal And Disassembly............................................................................................................. 61 Assembly And Installation .......................................................................................................... 61 Adjust The Parking Brake............................................................................................................ 62 MASTER CYLINDER......................................................................................................................... 65 Removal............................................................................................................................. 65 Cleaning And Inspection............................................................................................................. 65 Repair.............................................................................................................................. 65 Installation........................................................................................................................ 65 CHECKS AND ADJUSTMENTS...................................................................................................................... 67 ADJUST THE SERVICE BRAKES............................................................................................................... 67 ADJUST THE BRAKE PEDAL.................................................................................................................. 68 ADJUST THE MASTER CYLINDER.............................................................................................................. 68 REMOVE THE AIR FROM THE BRAKE SYSTEM.................................................................................................... 68 TEST THE "PARKING BRAKE NOT APPLIED" WARNING............................................................................................ 68 TROUBLESHOOTING............................................................................................................................. 69 TORQUE SPECIFICATIONS....................................................................................................................... 71 COUNTERWEIGHTS.............................................................................................................................. 72 HYDRAULIC SYSTEM............................................................................................................................ 72 WHEELS AND TIRES ........................................................................................................................... 73 BATTERY SPECIFICATIONS - E2.00-3.20XM (E45-65XM, E45-XM2, N30XMH, N30XMH2).................................................................. 73 BATTERY SPECIFICATIONS - J2.00-3.20XM (J40-65XM, J40-65XM2)................................................................................. 74 CAPACITIES.................................................................................................................................. 74 MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS................................................................................................. 74 E45-65XM MAST SPEEDS (36 or 48 Volt) Americas............................................................................................... 75 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 75 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 76 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 77 E40-65XM, E40-65XM2, N30XMH2 MAST SPEEDS (36 or 48 Volt) (3/99) Americas.................................................................... 78 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*................................................................................................ 78 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*................................................................................................ 79 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 80 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 80 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 81 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 82 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 83 CONTACTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.................................................................................. 83 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................................ 84 E2.00-3.20XM, E2.00-3.20XM2, MAST SPEEDS (72 or 80 Volt) (3/99) Europe...................................................................... 85 190 mm MOTOR & LARGE LIFT PUMP*......................................................................................................... 85 190 mm MOTOR & SMALL LIFT PUMP*......................................................................................................... 86 203 or 190 mm LONG STACK MOTOR & SMALL LIFT PUMP*....................................................................................... 87 J40-65XM MAST SPEEDS (36 or 48 Volt) Americas............................................................................................... 88 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 88 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 89 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 90 J40-65XM, J40-65XM2, MAST SPEEDS (36 or 48 Volt) (3/99) Americas............................................................................ 91 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*................................................................................................ 91 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*................................................................................................ 92 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 93 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................ 93 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 94 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*........................................................................ 95 CONT. OR TRANSISTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................ 96 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................................ 97 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) (3/99) Europe...................................................................................... 98 190 mm MOTOR & LARGE LIFT PUMP*......................................................................................................... 98 190 mm MOTOR & SMALL LIFT PUMP*......................................................................................................... 99 203 or 190 mm LONG STACK MOTOR & LARGE LIFT PUMP*.......................................................................................100 TORQUE SPECIFICATIONS.......................................................................................................................101 REFERENCE TABLE.............................................................................................................................104 INTRODUCTION................................................................................................................................105 ELECTRIC MOTOR MAINTENANCE, GENERAL.....................................................................................................105 BRUSH AND COMMUNICATOR INSPECTION.......................................................................................................105 Hydraulic Pump Motor And Traction Motor.............................................................................................105 Steering Pump Motor.................................................................................................................107 BRUSH WEAR REPLACEMENT GUIDE................................................................................................................107 Commutator Problems.....................................................................................................................109 BRUSH REPLACEMENTS......................................................................................................................111 DISASSEMBLY OF MOTORS...................................................................................................................113 Traction Motor And Hydraulic Pump Motor.............................................................................................113 Steering Pump Motor.................................................................................................................119 ASSEMBLY OF MOTORS......................................................................................................................121 Traction Motor And Hydraulic Pump Motor ............................................................................................121 Steering Pump Motor.................................................................................................................121 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS..........................................................................................121 TESTS FOR A DAMAGED FIELD AND ARMATURE..................................................................................................122 Test For An Open Circuit In The Armature............................................................................................122 Test For A Short-Circuit In One Armature Winding....................................................................................122 Test For A Short-Circuit To Armature Shaft..........................................................................................123 Test For An Open Circuit In A Field Coil............................................................................................123 Test For A Short-Circuit In A Field Coil............................................................................................123 Test For A Short-Circuit Between The Field And The Motor Case.......................................................................124 Brush Holder Test...................................................................................................................124 TROUBLESHOOTING.............................................................................................................................124 FIGURE 1. SCHEMATIC - EV - 100ZX SCR CONTROL FOR TRACTION MOTOR.............................................................................126 FIGURE 2. SCHEMATIC - EV - 100ZX SCR CONTROL FOR LIFT PUMP MOTOR............................................................................127 FIGURE 3. SCHEMATIC - CONTACTOR CONTROL FOR LIFT PUMP MOTOR.................................................................................128 FIGURE 4. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................130 FIGURE 5. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................132 FIGURE 6. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................134 FIGURE 7. WIRING CONNECTIONS, CONTROLLER PANEL-TOPANEL, E2.00-3.20XM (E45-65XM) AND N30XMH..................................................135 FIGURE 8. WIRING CONNECTIONS, CONTROLLER PANEL-TO-PANEL, J2.00-3.20XM (J40-65XM)............................................................136 FIGURE 9. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM)...........................................................................................138 FIGURE 10. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM)..........................................................................................140 FIGURE 11. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM)..........................................................................................142 FIGURE 12. TRUCK WIRING HARNESSES AND CABLES, E2.00-3.20XM (E45-65XM) AND N30XMH............................................................143 FIGURE 13. TRUCK POWER CABLES, E2.00-3.20XM (E45-65XM) AND N30XMH...........................................................................144 FIGURE 14. EV - 100 ZX SCR TRACTION AND PUMP MOTOR CONTROLLERS, E2.00-3.20XM (E45-65XM) AND N30XMH..........................................145 FIGURE 15. EV - 100 ZX SCR TRACTION MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL, E2.00-3.20XM (E45-65XM)....................................146 FIGURE 16. EV - 100ZX SCR TRACTION MOTOR AND SCR PUMP MOTOR CONTROLLERS, E2.00-3.20XM (E45-65XM) AND N30XMH.................................147 FIGURE 17. EV - 100ZX SCR TRACTION MOTOR CONTROLLER WITH CONTACTOR CONTROL OF PUMP MOTOR, E2.00-3.20XM (E45-65XM)...........................148 FIGURE 18. EV - 100ZX CONTACTOR PANEL, E2.00-3.20XM (E45-65XM) AND N30XMH...................................................................149 FIGURE 19. CHASSIS AND HYDRAULIC LINKAGE, SWITCH WIRING DETAILS, E2.00-3.20XM (E45-65XM) AND N30XMH.........................................150 FIGURE 20. TRUCK WIRING HARNESSES AND CABLES, J2.00-3.20XM (J40-65XM).......................................................................151 FIGURE 21. TRUCK POWER CANLES, J2.00-3.20XM (J40-65XM)......................................................................................152 FIGURE 22. EV - 100 ZX SCR TRACTION AND PUMP MOTOR CONTROLLERS, J2.00-3.20XM (J40-65XM).....................................................153 FIGURE 23. EV - 100 ZX SCR TRACTION MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL, J2.00-3.20XM (J40-65XM)....................................154 FIGURE 24. EV - 100ZX SCR TRACTION MOTOR AND SCR PUMP MOTOR CONTROLLERS, J2.00-3.20XM (J40-65XM)............................................155 FIGURE 25. EV - 100ZX SCR TRACTION MOTOR CONTROLLER WITH CONTACTOR CONTROL OF PUMP MOTOR, J2.00-3.20XM (J40-65XM)...........................156 FIGURE 26. EV - 100ZX CONTACTOR PANEL, J2.00-3.20XM (J40-54XM)..............................................................................157 FIGURE 27. CHASSIS AND HYDRAULIC LINKAGE, SWITCH WIRING DETAILS, J2.00-3.20XM (J40-65XM)....................................................158 FIGURE 28. STEERING COLUMN WIRING DETAIL....................................................................................................159 FIGURE 29. DISPLAY PANELS AND PLUG CONNECTORS...............................................................................................160 FIGURE 30. DETAIL OF BATTEY CONNECTORS WITH +12 VOLT TAP....................................................................................161 FIGURE 31. LIGHTING SCHEMATIC (CHASSIS).....................................................................................................162 FIGURE 32. LIGHTING SCHEMATIC (REAR), E2.00-3.02XM (E45-65XM) AND N30XMH....................................................................163 FIGURE 33. LIGHTING SCHEMATIC (REAR), J2.00-3.02XM (J40-65XM)...............................................................................164 FIGURE 34. LIGHTING WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH......................................................................166 FIGURE 35. LIGHTING WIRING DIAGRAM, J2.00-3.02XM (J40-65XM).................................................................................168 INTRODUCTION................................................................................................................................169 GENERAL.................................................................................................................................169 DESCRIPTION.............................................................................................................................169 REPAIRS.....................................................................................................................................171 REMOVAL OF THE DRIVE AXLE...............................................................................................................171 Disassembly of the Drive Axle.......................................................................................................172 Disassembly of the Transmission and Differential....................................................................................173 CLEANING................................................................................................................................175 INSPECTION..............................................................................................................................175 ASSEMBLY................................................................................................................................175 Assembly Of The Transmission And Differential.......................................................................................175 Assembly Of The Drive Axle..........................................................................................................181 INSTALLATION OF THE DRIVE AXLE ASSEMBLY.................................................................................................182 TROUBLESHOOTING.............................................................................................................................183 TORQUE SPECIFICATIONS.......................................................................................................................184 INTRODUCTION................................................................................................................................185 GENERAL.................................................................................................................................185 DESCRIPTION.............................................................................................................................185 REPAIRS.....................................................................................................................................185 REMOVAL.................................................................................................................................185 DISASSEMBLY.............................................................................................................................187 CLEANING................................................................................................................................189 INSPECTION..............................................................................................................................189 ASSEMBLY................................................................................................................................189 INSTALLATION............................................................................................................................192 TROUBLESHOOTING.............................................................................................................................193 TORQUE SPECIFICATIONS.......................................................................................................................193 ELECTRICAL SYSTEM...........................................................................................................................195 GENERAL.................................................................................................................................195 "LX" SERIES DISPLAY PANEL...............................................................................................................196 Hourmeter Functions.................................................................................................................197 Battery Indicator Function..........................................................................................................197 Status Code Function................................................................................................................198 "ZX" SERIES DISPLAY PANELS..............................................................................................................198 Display Panel.......................................................................................................................198 Basic Display Panels................................................................................................................198 Performance Display.................................................................................................................200 Brush Wear Indicators...............................................................................................................203 SEM DISPLAY PANELS - FEATURES...........................................................................................................203 Description Of Common Features......................................................................................................204 LED SYMBOL INDICATORS...............................................................................................................204 LCD SCREEN..........................................................................................................................204 BATTERY DISCHARGE INDICATOR (BDI)...................................................................................................204 SERVICE REMINDER....................................................................................................................204 STATUS CODES........................................................................................................................204 HOURMETER...........................................................................................................................204 Additional Features Of Premium Display Panel .......................................................................................204 Descriptions Of Additional Features (Available With The Premium Display) ...........................................................205 LCD SCREEN..........................................................................................................................205 OPERATOR PASSWORDS..................................................................................................................205 DAILY CHECK LIST AND SERVICE ITEMS..................................................................................................205 PERFORMANCE MODELS..................................................................................................................205 STATUS CODE LISTS...................................................................................................................205 ADJUSTMENTS OF BDI..................................................................................................................206 SEM DISPLAY PANEL INDICATORS............................................................................................................206 All Indicator Symbols...............................................................................................................206 Hourmeter Indicator Symbol..........................................................................................................207 Wrench Indicator Symbol.............................................................................................................207 Battery Indicator Symbol............................................................................................................207 Battery State-Of-Charge (BDI).......................................................................................................207 Brake Fluid Too Low Symbol..........................................................................................................207 Parking Brake Symbol................................................................................................................207 Fasten Seat Belt Symbol.............................................................................................................207 LCD "Screen" (Standard Display Panel)...............................................................................................207 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM.................................................................................207 Alpha Numeric "Screen"..............................................................................................................207 "Star" Push Button..................................................................................................................208 Push Buttons #1 Through #5..........................................................................................................208 OTHER CONTROL COMPONENTS................................................................................................................208 REPLACEMENT.................................................................................................................................209 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"................................................................................................209 Replace The Display Panel Assembly..................................................................................................209 Replace The Key Switch..............................................................................................................210 Indicator LEDs......................................................................................................................210 Battery Indicators..................................................................................................................210 Digital Display (Performance Display Panel Only) ...................................................................................210 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only)........................................212 Replace Parts Of The Basic Display Panel ...........................................................................................212 Replace Parts Of The Performance Display Panel......................................................................................213 SEM DISPLAY PANEL.......................................................................................................................214 Removal And Replacement.............................................................................................................214 REPLACE MOTOR CONTROLLER (SR or SP).....................................................................................................214 OTHER CONTROL COMPONENTS................................................................................................................214 Start Swtich........................................................................................................................214 Brake Light Switch..................................................................................................................215 Seat Switch.........................................................................................................................216 Adjust The External Seat Switch.....................................................................................................217 Switch For Optional Seat Brake......................................................................................................217 Parking Brake Switch................................................................................................................217 Direction Switches (Monotrol Pedal)................................................................................................218 Direction Control Switches (Steering Column)........................................................................................219 Direction Control Switches, E70-120XL3 (Steering Column)............................................................................220 Brake Fluid Switch..................................................................................................................220 Brush Wear And Over Temperature Sensors.............................................................................................220 Rocker Switches For Lights .........................................................................................................221 Accelerator Position Sensor.........................................................................................................221 On-Demand Steering Components.......................................................................................................223 Lights, Converter, Relay And Reverse Alarm..........................................................................................225 Horn And Horn Buttons...............................................................................................................228 Hydraulic Pump Switches.............................................................................................................229 CHECKS AND ADJUSTMENTS......................................................................................................................229 GENERAL.................................................................................................................................229 CONTROL AND POWER FUSES - "LX" OR "ZX"..................................................................................................229 CONTROL AND POWER FUSES - SEM...........................................................................................................232 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"............................................................................235 THERMAL SENSORS - SEM...................................................................................................................235 ADJUST THE START SWITCH.................................................................................................................235 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3...................................................................236 Direction Switches (MONOTROL).......................................................................................................238 ADJUST THE BRAKE LIGHT SWITCH.......................................................................................................238 CHECK SEAT SWITCH...................................................................................................................238 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE...........................................................................................238 ADJUST THE PARKING BRAKE SWITCH.....................................................................................................239 DIRECTIONAL SWITCHES................................................................................................................239 DIRECTIONAL SWITCHES (STEERING COLUMN)..............................................................................................239 HYDRAULIC PUMP SWITCHES.............................................................................................................239 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT......................................................................................239 ADJUST THE ACCELERATOR POSITION SENSOR..............................................................................................240 EV-100ZXE SCR MOTOR CONTROLLER, Description, Adjustments, Troubleshooting, Repairs, and Theory..............................................242 GENERAL.................................................................................................................................242 Model Number Data For EV-100ZX Controller...........................................................................................243 REGISTER PARAMETERS.....................................................................................................................252 General.............................................................................................................................252 Function Members....................................................................................................................252 CONTROL CARD, CHECKS AND ADJUSTMENTS....................................................................................................252 HAND SET................................................................................................................................253 How To Check And Adjust The Registers...............................................................................................253 How To Scroll Through The Fault Codes And Clear Them................................................................................253 Checks And Adjustments On The Work Bench............................................................................................254 When The Hand Set Is Connected To A Control Card Installed In A Lift Truck..........................................................255 FUNCTION NUMBER DESCRIPTIONS............................................................................................................256 TRACTION CONTROL CARDS (LABEL LETTERS - ZH AND ZY)......................................................................................257 PUMP CONTROL CARD (LABEL LETTER ZP).....................................................................................................263 REGISTER PARAMETERS.....................................................................................................................267 TROUBLESHOOTING.........................................................................................................................267 Status Codes........................................................................................................................268 REGISTER MAPS...........................................................................................................................268 STATUS CODE CHARTS..........................................................................................................................277 REPAIRS.....................................................................................................................................309 FUSES...................................................................................................................................310 CHECK AN SCR............................................................................................................................310 THE SCR ASSEMBLY........................................................................................................................311 THERMAL PROTECTOR.......................................................................................................................311 REPLACE THE SCR 1 ASSEMBLY..............................................................................................................311 THE "OFF" CIRCUIT FOR SCR 1.............................................................................................................311 Check The Reactor Assembly..........................................................................................................311 Check Suppressors For SCR 2 And SCR 5...............................................................................................312 Check SCR 2 And SCR 5...............................................................................................................312 Replace SCR 2 And SCR 5.............................................................................................................312 Check Capacitor C1..................................................................................................................312 DIODES D3 AND D4........................................................................................................................312 Check The Diodes D3 And D4..........................................................................................................313 Replacement, Diodes D3 And D4.......................................................................................................313 MOTOR CURRENT SENSOR....................................................................................................................313 CONTACTORS..............................................................................................................................313 Contactor Repair....................................................................................................................314 CONTROL CARD............................................................................................................................315 CONTROL CARD PLUGS......................................................................................................................316 Brush Wear Indicators...............................................................................................................317 THEORY OF OPERATION.........................................................................................................................318 ELECTRONIC SPEED CONTROLS...............................................................................................................318 The Silicon Controlled Rectifier (SCR)..............................................................................................318 A Motor Circuit That Operates With Pulses...........................................................................................318 Traction Circuit....................................................................................................................320 Hydraulic Pump Motor................................................................................................................320 The SCR 1 "OFF" Circuit.............................................................................................................321 INDUCTION CURRENT FROM THE MOTOR........................................................................................................323 CONTROL CARDS...........................................................................................................................323 Pulse Monitor Trip (PMT) (Traction Circuit Only)....................................................................................323 SRO Circuit (Traction Circuit Only).................................................................................................324 SEQUENCE OF OPERATION...................................................................................................................325 Control Card Adjustments (Traction Circuit).........................................................................................325 Accelerator Control.................................................................................................................328 SCR CONTROL (HYDRAULIC PUMP MOTOR)......................................................................................................328 CONTACTORS..............................................................................................................................329 CIRCUIT PROTECTION......................................................................................................................330 Traction Circuit Fuse...............................................................................................................330 Current Limit.......................................................................................................................330 Thermal Protection..................................................................................................................330 Suppressors.........................................................................................................................330 TRUCK MANAGEMENT MODULE (TMM1)..........................................................................................................330 TABLE 8. Terminal And Plug Wire Connections For TMM1 Module.........................................................................331 DISPLAY PANELS..........................................................................................................................331 Display Panel.......................................................................................................................331 Basic Display.......................................................................................................................331 Performance Display.................................................................................................................333 Brush Wear Indicators...............................................................................................................336 EV-100ZX SCR MOTOR CONTROLLER, Parameter Tables.............................................................................................337 REGISTER PARAMETERS.....................................................................................................................337 General.............................................................................................................................337 Function Numbers....................................................................................................................338 CONTROL CARD, CHECKS AND ADJUSTMENTS....................................................................................................338 REGISTER PARAMETERS.....................................................................................................................338 TABLE 1. EV-100ZX Parameters - E/J2.00-3.20XM (E/J45-65XM) and N30XMH (36 to 48V)(Traction Card Type ZH With Regenerative Brakin....339 TABLE 2. EV-100ZX Parameters - E2.00-3.20XM (E45-65XM) and N30XMH (36 to 48V)(Traction Card Type ZY NO Regenerative Braking and ....342 TABLE 3. EV-100ZX Parameters - E/J2.00-3.20XM (72 to 80V)(Traction Card Type ZH with Regenerative Braking and Field Weakening.......345 TABLE 4. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V)(Traction Card Type ZY With Regenerative Braking And NO Field Weakening......348 TABLE 5. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V)(Low Energy Usage)(Traction Card Type ZY With 9-inch Motor, Regenerative.....351 TABLE 6. EV-100ZX Parameters - All Lift Trucks (36 to 48 volts)(Hydraulic Pump Card Type ZP)........................................354 TABLE 7. EV-100ZX Parameters - All Lift Trucks (72 to 80 volts)(Hydraulic Pump Card Type ZP)........................................357 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers....................................360 COMPUTER SYSTEM.........................................................................................................................360 Connect A PC To A Control Card......................................................................................................361 HYTECt SOFTWARE PROGRAM ................................................................................................................362 How To Start The Program............................................................................................................362 Selecting The Communications Port...................................................................................................363 Verification Of Controller and Lift Truck...........................................................................................363 Select The Lift Truck Series........................................................................................................364 Undefined Controller Card...........................................................................................................365 Controller Card Register Parameter List.............................................................................................365 How To Enter A New Parameter........................................................................................................366 How To Save A Changed Parameter File................................................................................................367 How To Load A Saved Parameter File..................................................................................................367 How To Return To Factory Default Settings...........................................................................................368 How To Save Changes To The Controller Card..........................................................................................369 How To View The Status Codes .......................................................................................................369 Saving The Status Code To Disk......................................................................................................370 Closing and Clearing The Status Code List...........................................................................................371 COMMUNICATIONS PROGRAM (MODEM)..........................................................................................................371 Requirements........................................................................................................................372 README File.........................................................................................................................373 GE Sentry Software......................................................................................................................373 Getting Started.....................................................................................................................373 Where To Get Help...................................................................................................................374 Hardware and Software Requirements..................................................................................................374 Installation of the GE SENTRY SOFTWARE..............................................................................................374 How To Start The GE SENTRY Program..................................................................................................374 How To Reset The MIN and MAX Display................................................................................................376 How To Exit The GE SENTRY Program...................................................................................................376 INTRODUCTION................................................................................................................................377 GENERAL.................................................................................................................................377 DESCRIPTION.............................................................................................................................377 Main Frame..........................................................................................................................377 Other Frame Weldments...............................................................................................................377 Battery Restraint/Hood Frame And Plate For Optional Seat Brake......................................................................379 Overhead Guard......................................................................................................................380 REPAIRS.....................................................................................................................................381 OVERHEAD GUARD..........................................................................................................................381 Removal.............................................................................................................................381 Installation........................................................................................................................381 BATTERY RESTRAINT AND SEAT ASSEMBLY.....................................................................................................381 COUNTERWEIGHT...........................................................................................................................382 Removal.............................................................................................................................382 Installation........................................................................................................................383 TRACTION MOTOR..........................................................................................................................383 Removal.............................................................................................................................383 Installation........................................................................................................................385 HYDRAULIC TANK..........................................................................................................................385 Inspection..........................................................................................................................385 Repairs, Small Leaks................................................................................................................385 Repairs, Large Leaks................................................................................................................386 Cleaning............................................................................................................................386 Steam Method Of Cleaning............................................................................................................386 Chemical Solution Method Of Cleaning................................................................................................386 Additional Preparations For Repair..................................................................................................387 PAINTING INSTRUCTIONS...................................................................................................................388 LABEL REPLACEMENT.......................................................................................................................389 INTRODUCTION................................................................................................................................391 GENERAL ................................................................................................................................391 DESCRIPTION.............................................................................................................................391 Main Frame..........................................................................................................................391 Other Frame Weldments...............................................................................................................391 Battery Restraint/Hood Frame........................................................................................................391 Overhead Guard......................................................................................................................397 REPAIRS.....................................................................................................................................397 OVERHEAD GUARD..........................................................................................................................397 Removal.............................................................................................................................397 Installation........................................................................................................................397 BATTERY RESTRAINT AND SEAT ASSEMBLY.....................................................................................................397 Removal.............................................................................................................................397 COUNTERWEIGHT...........................................................................................................................398 Counterweight Removal...............................................................................................................398 Counterweight Installation..........................................................................................................399 TRACTION MOTOR..........................................................................................................................399 Motor Removal.......................................................................................................................399 Motor Installation..................................................................................................................400 HYDRAULIC TANK..........................................................................................................................401 Tank Removal........................................................................................................................401 Tank Inspection.....................................................................................................................401 Tank Repairs, Small Leaks...........................................................................................................401 Tank Repairs, Large Leaks...........................................................................................................401 Tank Cleaning.......................................................................................................................402 Steam Method Of Cleaning Tank.......................................................................................................402 Chemical Solution Method Of Cleaning Tank...........................................................................................402 Additional Preparations For Tank Repair.............................................................................................402 Tank Installation (See FIGURE 10.)..................................................................................................403 PAINTING INSTRUCTIONS...................................................................................................................404 LABEL REPLACEMENT.......................................................................................................................404 INTRODUCTION................................................................................................................................408 GENERAL.................................................................................................................................408 DESCRIPTION AND OPERATION...............................................................................................................408 Carriages...........................................................................................................................408 Mast Mounts.........................................................................................................................409 TWO-STAGE MAST, LIMITED FREE-LIFT.......................................................................................................410 Description and Operation...........................................................................................................410 TWO-STAGE MAST, FULL FREE-LIFT..........................................................................................................412 Description.........................................................................................................................412 Operation...........................................................................................................................412 THREE-STAGE, FULL FREE-LIFT MAST........................................................................................................414 Description.........................................................................................................................414 Operation...........................................................................................................................414 INTRODUCTION ...............................................................................................................................416 GENERAL ................................................................................................................................416 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ...............................................................................................416 REPAIRS ....................................................................................................................................417 FORKS ..................................................................................................................................417 Removal ............................................................................................................................417 Installation .......................................................................................................................418 CARRIAGES ..............................................................................................................................418 Removal, Standard Carriage .........................................................................................................418 Removal, Side–Shift Carriage .......................................................................................................419 Repairs ............................................................................................................................419 Installation, Standard Carriage ....................................................................................................419 Installation, Side–Shift Carriage ..................................................................................................420 MAST ...................................................................................................................................421 Removal ............................................................................................................................421 Disassembly, Three–Stage FFL Mast ..................................................................................................427 Disassembly, Two–Stage LFL And Two–Stage FFL Masts .................................................................................421 Cleaning and Inspection ............................................................................................................427 Assembly, Two–Stage LFL And Two–Stage FFL Mast .....................................................................................430 Assembly, Three–Stage FFL Mast .....................................................................................................431 Installation, Mast .................................................................................................................432 LIFT CYLINDERS .........................................................................................................................433 Removal, Main Lift Cylinders .......................................................................................................433 Removal, Free–Lift Cylinder ........................................................................................................433 Disassembly, Lift Cylinders ........................................................................................................433 Assembly, Lift Cylinders ...........................................................................................................434 Installation, Main Lift Cylinders ..................................................................................................435 Installation, Free–Lift Cylinder ...................................................................................................436 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) ...........................................437 New Hose Installation, Two–Stage, LFL Mast .........................................................................................437 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .........................................................................437 New Hose Installation, Two–Stage FFL Mast ..........................................................................................441 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .........................................................................441 New Hose Installation, Three–Stage FFL Mast ........................................................................................445 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ......................................................................450 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) ...........................452 New Hose Installation, Two–Stage LFL Mast ..........................................................................................453 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .........................................................................453 New Hose Installation, Two–Stage FFL Mast ..........................................................................................456 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .........................................................................456 New Hose Installation, Three–Stage, FFL Mast .......................................................................................460 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ......................................................................465 CHECKS AND ADJUSTMENTS .....................................................................................................................466 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ...........................................................................................466 Check The Lift Cylinders For Leaks ................................................................................................466 Check The Tilt Cylinders For Leaks ................................................................................................466 ADJUST THE TILT CYLINDERS .............................................................................................................466 ADJUST THE LIFT CHAINS ................................................................................................................467 ADJUST THE MAST .......................................................................................................................468 ADJUST THE CARRIAGE ...................................................................................................................469 TROUBLESHOOTING.............................................................................................................................470 INTRODUCTION................................................................................................................................471 GENERAL.................................................................................................................................471 DESCRIPTION.............................................................................................................................472 Hydraulic System....................................................................................................................472 OPERATION...............................................................................................................................472 Hydraulic System....................................................................................................................472 Hydraulic Gear Pump.................................................................................................................473 Rotator Actuator Valve..............................................................................................................473 Steering Pump.......................................................................................................................476 REPAIRS.....................................................................................................................................480 HYDRAULIC TANK..........................................................................................................................480 E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal.....................................................................................480 J2.00-3.20XM (J40-65XM) Tank Removal................................................................................................480 Tank Inspection.....................................................................................................................480 Tank Repairs, Small Leaks...........................................................................................................481 Tank Repairs, Large Leaks ..........................................................................................................481 Tank Cleaning.......................................................................................................................481 Steam Method Of Cleaning Tank.......................................................................................................481 Chemical Solution Method Of Cleaning Tank...........................................................................................481 Additional Preparations For Tank repair.............................................................................................482 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation................................................................................482 J2.00-3.20XM (J40-65XM) Tank Installation...........................................................................................482 FILTER REPLACEMENT......................................................................................................................483 HYDRAULIC PUMP..........................................................................................................................483 Removing E1.50-3.20XM (E25-65XM) and N30XMH Hydraulic Pump..........................................................................483 Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump...................................................................................484 Pump Seal Replacement And Pump Assembly.............................................................................................484 Assemble Pump On The Motor..........................................................................................................486 Install The Hydraulic Pump And Motor Assembly [E1.50-3.20XM (E25-65XM) and N30XMH]..................................................487 Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly...................................................................487 MAIN CONTROL VALVE......................................................................................................................488 STEERING PUMP...........................................................................................................................488 Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N30XMH....................................................................488 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM)...............................................................................489 Pump Assembly And Installation......................................................................................................490 ROTARY ACTUATOR VALVE...................................................................................................................491 Disassembly, Cleaning and Inspection................................................................................................491 Assembly............................................................................................................................491 STEERING CONTROL UNIT...................................................................................................................491 Control Unit Removal................................................................................................................492 Control Unit Installation...........................................................................................................492 STEERING CYLINDER.......................................................................................................................492 CHECKS AND ADJUSTMENTS......................................................................................................................494 MAIN CONTROL VALVE......................................................................................................................494 STEERING RELIEF VALVE...................................................................................................................494 TROUBLESHOOTING CHART.......................................................................................................................494 SPECIFICATIONS..............................................................................................................................498 INTRODUCTION................................................................................................................................501 GENERAL.................................................................................................................................501 LEAD-ACID BATTERIES.....................................................................................................................501 SPECIFIC GRAVITY........................................................................................................................502 CHEMICAL REACTION IN A CELL.............................................................................................................502 ELECTRICAL TERMS........................................................................................................................503 HOW TO SELECT THE BATTERY...............................................................................................................503 VOLTAGE OF A BATTERY....................................................................................................................503 THE BATTERY AS A COUNTERWEIGHT..........................................................................................................504 BATTERY RATINGS.........................................................................................................................504 Kilowatt-Hours......................................................................................................................505 BATTERY MAINTENANCE.........................................................................................................................505 SAFETY PROCEDURES.......................................................................................................................505 MAINTENCE RECORDS.......................................................................................................................506 THE NEW BATTERY.........................................................................................................................506 HOW TO CLEAN THE BATTERY................................................................................................................507 HOW TO ADD WATER........................................................................................................................507 THE HYDROMETER..........................................................................................................................508 BATTERY TEMPERATURE.....................................................................................................................508 CHARGING THE BATTERY....................................................................................................................509 Types Of Battery Charges............................................................................................................510 Methods Of Charging.................................................................................................................511 Troubleshooting The Charger.........................................................................................................511 How to Know When The Battery Is Fully Charged.......................................................................................512 WHERE TO CHARGE THE BATTERIES...........................................................................................................512 Equipment Needed....................................................................................................................512 BATTERY CONNECTORS......................................................................................................................513 BATTERY CARE............................................................................................................................513 INTRODUCTION................................................................................................................................515 GENERAL.................................................................................................................................515 DESCRIPTION.............................................................................................................................515 REPAIRS.....................................................................................................................................519 REMOVAL AND DISASSEMBLY.................................................................................................................519 ASSEMBLY AND INSTALLATION...............................................................................................................519 INTRODUCTION................................................................................................................................522 GENERAL.................................................................................................................................522 DESCRIPTION.............................................................................................................................522 OPERATION...............................................................................................................................523 E1.50-3.20XM (E25-65XM).............................................................................................................524 J2.00-3.20XM (J40-65XM).............................................................................................................524 Lift Section........................................................................................................................524 Tilt Section........................................................................................................................525 Relief Valve........................................................................................................................527 REPAIRS.....................................................................................................................................528 MAIN CONTROL VALVE......................................................................................................................528 Removal.............................................................................................................................528 Disassembly.........................................................................................................................528 Cleaning And Inspection.............................................................................................................528 Assembly............................................................................................................................528 Installation, E1.50-3.20XM (E25-65XM)...............................................................................................530 Installation, J2.00-3.20XM (J40-65XM)...............................................................................................532 CONTROL LEVER LINKAGE, E1.50-3.20XM (E25-65XM)..........................................................................................533 Removal.............................................................................................................................533 Disassembly.........................................................................................................................534 Assembly And Installation...........................................................................................................534 CONTROL VALVE LINKAGE, E1.50-3.20XM (E25-65XM)..........................................................................................534 Removal And Disassembly.............................................................................................................534 Assembly And Installation...........................................................................................................535 CONTROL LEVER LINKAGE, J2.00-3.20XM (J40-65XM)..........................................................................................535 Removal.............................................................................................................................535 Disassembly.........................................................................................................................535 Assembly And Installation...........................................................................................................537 CHECKS AND ADJUSTMENTS......................................................................................................................538 PRESSURE RELIEF VALVES..................................................................................................................538 Primary Relief Valve................................................................................................................538 Secondary Relief Valve..............................................................................................................538 TROUBLESHOOTING.............................................................................................................................539 INTRODUCTION................................................................................................................................541 GENERAL.................................................................................................................................541 SERIAL NUMBER DATA......................................................................................................................541 HOW TO MOVE A DISABLED LIFT TRUCK.......................................................................................................541 How To Tow A Lift Truck ............................................................................................................541 HOW TO PUT A LIFT TRUCK ON BLOCKS.......................................................................................................542 How To Raise The Drive Tires........................................................................................................542 How To Raise The Steering Tires.....................................................................................................542 MAINTENANCE SCHEDULE........................................................................................................................543 MAINTENANCE PROCEDURES......................................................................................................................546 EVERY 8 HOURS OR DAILY......................................................................................................................546 Tires And Wheels........................................................................................................................546 Forks...................................................................................................................................547 Fork Adjustment.........................................................................................................................547 Fork Removal............................................................................................................................547 Fork Installation.......................................................................................................................548 Inspection Of Forks, Mast And Lift Chains...............................................................................................548 Safety Labels...........................................................................................................................549 Steering Column Latch...................................................................................................................549 Operator Restraint System...............................................................................................................550 Battery Restraint System, E25-65XM, E25-65XM2..........................................................................................550 Battery Restraint System - J40-65XM-65XM, J40-65XM2....................................................................................551 Battery.................................................................................................................................551 Hydraulic System........................................................................................................................552 HOW TO MAKE CHECKS WITH THE KEY "ON"....................................................................................................553 Gauges, Horn And Fuses..............................................................................................................553 Steering System.....................................................................................................................553 Service Brake.......................................................................................................................553 Parking Brake.......................................................................................................................554 Control Levers And Pedals...........................................................................................................554 Lift System Operation...............................................................................................................554 EVERY 350 HOURS OR THREE MONTHS ............................................................................................................555 HYDRAULIC TANK BREATHER.................................................................................................................555 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................555 WHEEL NUT TORQUES.......................................................................................................................556 STEERING AXLE SPINDLES..................................................................................................................556 MAST....................................................................................................................................556 LIFT CHAINS.............................................................................................................................557 Check For Wear......................................................................................................................557 Lubrication.........................................................................................................................557 FORKS...................................................................................................................................557 BRAKE FLUID.............................................................................................................................558 OTHER LUBRICATION.......................................................................................................................558 SEAT BRAKE (E25-65XM, E25-65XM2 Only....................................................................................................558 ELECTRICAL INSPECTION...................................................................................................................558 Contactors..........................................................................................................................559 Motor Brushes.......................................................................................................................559 Motor Brushes, General..............................................................................................................559 EVERY 2000 HOURS OR YEARLY..................................................................................................................569 HYDRAULIC SYSTEM........................................................................................................................569 Change The Filter For The Hydraulic Oil.............................................................................................569 Change The Hydraulic Oil............................................................................................................570 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................570 SERVICE BRAKES..........................................................................................................................570 CONTACTORS..............................................................................................................................571 WHEEL BEARINGS..........................................................................................................................571 Steer Wheels, Lubrication...........................................................................................................571 Drive Wheels, Lubrication...........................................................................................................571 LIFT CHAINS.............................................................................................................................571 GENERAL PROCEDURE...........................................................................................................................571 HOW TO CHARGE THE BATTERY...............................................................................................................571 HOW TO CHANGE THE BATTERY...............................................................................................................573 General.............................................................................................................................573 Change The E25-65XM, E25-65XM2 Battery..............................................................................................573 Change The J40-65XM, J40-65XM2 Battery..............................................................................................575 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................................577 Check The Lift Cylinders For Leaks..................................................................................................577 Check The Tilt Cylinders For Leaks..................................................................................................577 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)...................................................................................578 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)...................................................................................579 LIFT CHAIN ADJUSTMENTS..................................................................................................................579 HOW TO CHECK THE PMT CIRCUIT............................................................................................................580 WELDING REPAIRS.........................................................................................................................581 CHANGES TO THE OVERHEAD GUARD...........................................................................................................581 TIRES AND WHEELS, E25-65XM, E25-65XM2...................................................................................................581 Remove The Wheels From The Lift Truck..............................................................................................582 Remove And Install The Tire On The Wheel............................................................................................582 PNEUMATIC TIRES AND WHEELS J40-65XM, J40-65XM2..........................................................................................582 Remove The Wheels From The Lift Truck...............................................................................................582 Remove The Wheel From The Pneumatic Tire............................................................................................583 Install The Wheel In The Pneumatic Tire.............................................................................................584 Add Air To The Tires................................................................................................................585 Install The Wheels..................................................................................................................585 SOLID RUBBER TIRES ON PNEUMATIC WHEELS..................................................................................................585 Remove The Wheels From The Lift Truck...............................................................................................585 Remove The Solid Rubber Tire From The Pneumatic Wheel...............................................................................585 Install The Solid Rubber Tire On The Pneumatic Wheel................................................................................587 Install The Wheels .................................................................................................................587 REFERENCE TABLE.............................................................................................................................588 Adhesive And Sealants ..................................................................................................................588 INTRODUCTION................................................................................................................................589 NOMENCLATURE, THREADS...................................................................................................................589 STRENGTH IDENTIFICATION.................................................................................................................590 TABLE 1. BOLTS AND SCREWS...................................................................................................................590 TABLE 2. STUDS AND NUTS.....................................................................................................................591 TABLE 3. TORQUE NUTS........................................................................................................................592 TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................................593 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................................594 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................................595 INTRODUCTION................................................................................................................................598 GENERAL.................................................................................................................................598 DESCRIPTION.............................................................................................................................598 REPAIRS.....................................................................................................................................599 STEERING AXLE ASSEMBLY..................................................................................................................599 Removal.............................................................................................................................599 Installation........................................................................................................................599 WHEELS..................................................................................................................................599 Removal And Disassembly.............................................................................................................599 Cleaning............................................................................................................................599 Assembly And Installation...........................................................................................................600 SPINDLES, BEARINGS, AND TIE RODS........................................................................................................600 Removal And Disassembly.............................................................................................................600 Assembly And Installation...........................................................................................................601 STEERING CYLINDER.......................................................................................................................602 Removal And Disassembly.............................................................................................................602 Cleaning And Inspection.............................................................................................................602 Assembly And Installation...........................................................................................................602 TROUBLESHOOTING.............................................................................................................................603 TORQUE SPECIFICATIONS.......................................................................................................................603 STEERING SYSTEM.............................................................................................................................605 GENERAL.................................................................................................................................605 DESCRIPTION.............................................................................................................................607 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................608 Removal Of The Assembly Components..................................................................................................608 Installation Of The Assembly Components.............................................................................................612 POWER STEERING MOTOR AND PUMP...............................................................................................................613 DESCRIPTION.............................................................................................................................613 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)......................................613 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)...........................................................................613 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)........................................................................................614 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL).......................................................................................616 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)......................................................................................617 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]..........................................617 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)......................................................................................618 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)....................................................................................620 REPAIRS, POWER STEERING PUMP............................................................................................................621 Seal Replacement....................................................................................................................622 HYDRAULIC STEERING MOTOR....................................................................................................................622 DESCRIPTION.............................................................................................................................622 REPAIRS, HYDRAULIC STEERING MOTOR.......................................................................................................623 Removal ............................................................................................................................623 Disassembly.........................................................................................................................623 Cleaning And Inspection.............................................................................................................623 Assembly............................................................................................................................624 Installation, Hydraulic Steering Motor..............................................................................................625 CHECKS AND ADJUSTMENTS......................................................................................................................625 AIR IN THE STEERING SYSTEM..............................................................................................................625 CHECK STEERING PRESSURE.................................................................................................................625 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)...........................................................................626 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS...........................................................................................627 TROUBLESHOOTING.............................................................................................................................629 INTRODUCTION................................................................................................................................632 GENERAL.................................................................................................................................632 DESCRIPTION.............................................................................................................................632 OPERATION...............................................................................................................................632 REPAIRS.....................................................................................................................................633 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................633 Removal of the Assembly Components..................................................................................................637 Disassembly of the Steering Control Unit............................................................................................638 Cleaning of the Steering Control Unit...............................................................................................638 Assembly of the Steering Control Unit...............................................................................................638 Installation of the Steering Control Unit...........................................................................................638 Installation of the Assembly Components.............................................................................................638 CHECKS AND ADJUSTMENTS......................................................................................................................646 REMOVE AIR FROM THE SYSTEM..............................................................................................................646 TROUBLESHOOTING.............................................................................................................................646
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
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