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Hyster F108 (E45-65XM₂, J40-65XM₂) Service Manual – PDF DOWNLOAD
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Description
Hyster F108 (E45-65XM₂, J40-65XM₂) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster F108 (E45-65XM₂, J40-65XM₂) Service Manual – PDF DOWNLOAD
Language : English
Pages : 681
Downloadable : Yes
File Type : PDF
Size: 18.4 MB
TABLE OF CONTENTS:
Hyster F108 (E45-65XM₂, J40-65XM₂) Service Manual – PDF DOWNLOAD
Brake System (E45-65XM₂).................................................................................................................... 1 INTRODUCTION............................................................................................................................ 1 GENERAL............................................................................................................................. 1 DESCRIPTION AND OPERATION........................................................................................................... 1 Service Brakes.................................................................................................................. 1 Master Cylinder................................................................................................................. 1 Parking Brake................................................................................................................... 3 SERVICE BRAKES...................................................................................................................... 3 Removal And Disassembly......................................................................................................... 3 Cleaning........................................................................................................................ 5 Inspection...................................................................................................................... 6 Assembly And Installation....................................................................................................... 6 Adjustments..................................................................................................................... 8 PARKING BRAKE....................................................................................................................... 8 Removal And Disassembly......................................................................................................... 8 Assembly And Installation....................................................................................................... 9 Adjust The Parking Brake........................................................................................................ 9 MASTER CYLINDER..................................................................................................................... 12 Removal......................................................................................................................... 12 Cleaning And Inspection......................................................................................................... 12 Repair.......................................................................................................................... 12 Installation.................................................................................................................... 12 SEAT BRAKE ASSEMBLY................................................................................................................. 15 CHECKS AND ADJUSTMENTS.................................................................................................................. 16 ADJUST THE SERVICE BRAKES........................................................................................................... 16 ADJUST THE BRAKE PEDAL.............................................................................................................. 16 ADJUST THE MASTER CYLINDER.......................................................................................................... 16 REMOVE THE AIR FROM THE BRAKE SYSTEM................................................................................................ 16 TEST THE "PARKING BRAKE NOT APPLIED" WARNING........................................................................................ 16 TROUBLESHOOTING......................................................................................................................... 17 TORQUE SPECIFICATIONS................................................................................................................... 19 Brake System (J40-65XM₂).................................................................................................................... 22 INTRODUCTION............................................................................................................................ 22 GENERAL............................................................................................................................. 22 DESCRIPTION AND OPERATION........................................................................................................... 22 Service Brakes.................................................................................................................. 22 Master Cylinder .................................................................................................................... 22 Parking Brake................................................................................................................... 22 SERVICE BRAKES...................................................................................................................... 24 Removal And Disassembly......................................................................................................... 24 Cleaning........................................................................................................................ 26 Inspection...................................................................................................................... 26 Assembly And Installation....................................................................................................... 27 Adjustments..................................................................................................................... 28 PARKING BRAKE....................................................................................................................... 30 Removal And Disassembly......................................................................................................... 30 Assembly And Installation ...................................................................................................... 30 Adjust The Parking Brake........................................................................................................ 31 MASTER CYLINDER..................................................................................................................... 34 Removal......................................................................................................................... 34 Cleaning And Inspection......................................................................................................... 34 Repair.......................................................................................................................... 34 Installation.................................................................................................................... 34 CHECKS AND ADJUSTMENTS.................................................................................................................. 36 ADJUST THE SERVICE BRAKES........................................................................................................... 36 ADJUST THE BRAKE PEDAL.............................................................................................................. 37 ADJUST THE MASTER CYLINDER.......................................................................................................... 37 REMOVE THE AIR FROM THE BRAKE SYSTEM................................................................................................ 37 TEST THE "PARKING BRAKE NOT APPLIED" WARNING........................................................................................ 37 TROUBLESHOOTING......................................................................................................................... 38 TORQUE SPECIFICATIONS................................................................................................................... 40 Capacities & Specification.................................................................................................................. 41 COUNTERWEIGHTS.......................................................................................................................... 41 HYDRAULIC SYSTEM........................................................................................................................ 41 WHEELS AND TIRES ....................................................................................................................... 42 BATTERY SPECIFICATIONS - E2.00-3.20XM (E45-65XM, E45-XM2, N30XMH, N30XMH2).............................................................. 42 BATTERY SPECIFICATIONS - J2.00-3.20XM (J40-65XM, J40-65XM2)............................................................................. 43 CAPACITIES.............................................................................................................................. 43 MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS............................................................................................. 43 E45-65XM MAST SPEEDS (36 or 48 Volt) Americas........................................................................................... 44 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.............................................................................. 44 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................... 45 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.............................................................................. 46 E40-65XM, E40-65XM2, N30XMH2 MAST SPEEDS (36 or 48 Volt) (3/99) Americas................................................................ 47 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*............................................................................................ 47 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*............................................................................................ 48 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe......................................................................................... 49 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.............................................................................. 49 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................... 50 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.............................................................................. 51 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe......................................................................................... 52 CONTACTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.............................................................................. 52 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.................................................................................... 53 E2.00-3.20XM, E2.00-3.20XM2, MAST SPEEDS (72 or 80 Volt) (3/99) Europe.................................................................. 54 190 mm MOTOR & LARGE LIFT PUMP*..................................................................................................... 54 190 mm MOTOR & SMALL LIFT PUMP*..................................................................................................... 55 203 or 190 mm LONG STACK MOTOR & SMALL LIFT PUMP*................................................................................... 56 J40-65XM MAST SPEEDS (36 or 48 Volt) Americas........................................................................................... 57 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.............................................................................. 57 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................... 58 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.............................................................................. 59 J40-65XM, J40-65XM2, MAST SPEEDS (36 or 48 Volt) (3/99) Americas........................................................................ 60 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*............................................................................................ 60 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*............................................................................................ 61 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe......................................................................................... 62 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................... 62 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................... 63 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................... 64 CONT. OR TRANSISTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.................................................................... 65 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.................................................................................... 66 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) (3/99) Europe.................................................................................. 67 190 mm MOTOR & LARGE LIFT PUMP*..................................................................................................... 67 190 mm MOTOR & SMALL LIFT PUMP*..................................................................................................... 68 203 or 190 mm LONG STACK MOTOR & LARGE LIFT PUMP*................................................................................... 69 TORQUE SPECIFICATIONS................................................................................................................... 70 REFERENCE TABLE......................................................................................................................... 73 DC Motor Maintenance........................................................................................................................ 74 INTRODUCTION............................................................................................................................ 74 ELECTRIC MOTOR MAINTENANCE, GENERAL................................................................................................. 74 BRUSH AND COMMUNICATOR INSPECTION................................................................................................... 74 Hydraulic Pump Motor And Traction Motor......................................................................................... 74 Steering Pump Motor............................................................................................................. 76 BRUSH WEAR REPLACEMENT GUIDE............................................................................................................ 76 Commutator Problems................................................................................................................. 78 BRUSH REPLACEMENTS.................................................................................................................. 80 DISASSEMBLY OF MOTORS............................................................................................................... 82 Traction Motor And Hydraulic Pump Motor......................................................................................... 82 Steering Pump Motor............................................................................................................. 88 ASSEMBLY OF MOTORS.................................................................................................................. 90 Traction Motor And Hydraulic Pump Motor ........................................................................................ 90 Steering Pump Motor............................................................................................................. 90 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS...................................................................................... 90 TESTS FOR A DAMAGED FIELD AND ARMATURE.............................................................................................. 91 Test For An Open Circuit In The Armature........................................................................................ 91 Test For A Short-Circuit In One Armature Winding................................................................................ 91 Test For A Short-Circuit To Armature Shaft...................................................................................... 92 Test For An Open Circuit In A Field Coil........................................................................................ 92 Test For A Short-Circuit In A Field Coil........................................................................................ 92 Test For A Short-Circuit Between The Field And The Motor Case................................................................... 93 Brush Holder Test............................................................................................................... 93 TROUBLESHOOTING......................................................................................................................... 93 Diagrams.................................................................................................................................... 95 FIGURE 1. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (E25-65XM2).................................................. 95 FIGURE 2. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (E25-65XM2)............................................................ 96 FIGURE 3. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (E25-65XM2).............................................................. 97 FIGURE 4. WIRING DIAGRAM - COMMON CONCEPTS (E25-65XM2) (SEM)............................................................................ 98 FIGURE 5. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLER (E25-65XM2)................................................................. 99 FIGURE 6. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (E25-65XM2)...................................100 FIGURE 7. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (N30XMH2)....................................................101 FIGURE 8. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (N30XMH2)..............................................................102 FIGURE 9. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (N30XMH2)................................................................103 FIGURE 10. WIRING DIAGRAM - COMMON COMPONENTS (N30XMH2).................................................................................104 FIGURE 11. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLERS (N30XMH2).................................................................105 FIGURE 12. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (N30XMH2)....................................106 FIGURE 13. ELECTRICAL WIRING CONNECTORS (E25-65XM2) (N30XMH2)...........................................................................107 FIGURE 14. SCHEMATIC DIAGRAM - SR (SEM) MOTOR CONTROLLER FOR TRACTION MOTOR (J40-65XM2).................................................108 FIGURE 15. SCHEMATIC DIAGRAM - SP MOTOR CONTROLLER FOR PUMP MOTOR (J40-65XM2)...........................................................109 FIGURE 16. SCHEMATIC DIAGRAM - CONTACTOR CONTROL FOR PUMP MOTOR (J40-65XM2).............................................................110 FIGURE 17. WIRING DIAGRAM - COMMON COMPONENTS (J40-65XM2)...............................................................................111 FIGURE 18. WIRING DIAGRAM - SR (SEM) AND SP MOTOR CONTROLLER (J40-65XM2)................................................................112 FIGURE 19. WIRING DIAGRAM - SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL FOR PUMP MOTOR (J40-65XM2)..................................113 FIGURE 20. ELECTRICAL WIRING CONNECTORS (J40-65XM2).....................................................................................114 FIGURE 21. STEERING COLUMN WIRING DETAIL (E25-40XM2)....................................................................................115 FIGURE 22. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS (E25-40XM2)..............................................................116 FIGURE 23. TRUCK WIRING (E25-40XM2).....................................................................................................117 FIGURE 24. TRUCK POWER CABLES (E25-40XM2)...............................................................................................118 FIGURE 25. STEERING COLUMN WIRING DETAIL (E40-65XM2, J40-65XM2 AND N30XMH2).............................................................119 FIGURE 26. HYDRAULIC LINKAGE SWITCH AND CHASSIS WIRING DETAILS (E40-65XM2, J40-65XM2 AND N30XMH2).......................................120 FIGURE 27. TRUCK WIRING (E40-65XM2, J40-65XM2 AND N30XMH2)..............................................................................121 FIGURE 28. TRUCK POWER CABLES (E40-65XM2, J40-65XM2 AND N30XMH2)........................................................................122 FIGURE 29. PANEL WIRING WITH SR (SEM) AND SP MOTOR CONTROLLERS..........................................................................123 FIGURE 30. PANEL WIRING WITH SR (SEM) MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL.......................................................124 FIGURE 31. SR (SEM) AND SP MOTOR CONTROLLERS............................................................................................125 FIGURE 32. SR (SEM) MOTOR CONTROLLER AND CONTACTOR CONTROL OF PUMP MOTOR................................................................126 FIGURE 33. (SEM) DISPLAY PANELS.........................................................................................................127 FIGURE 34. (SEM) DISPLAY PANEL CONNECTIONS AND MOUNTING.................................................................................128 FIGURE 35. LIGHTING SCHEMATIC DIAGRAM (E25-65XM2, J40-65XM2 AND N30XMH2)................................................................129 FIGURE 36. LIGHT WIRING DIAGRAM (E25-40XM2).............................................................................................131 FIGURE 37. LIGHT WIRING DIAGRAM (E45-65XM2 AND N30XMH2).................................................................................133 Drive Axle Speed Reducer Differential (E45-65XM-2)..........................................................................................136 INTRODUCTION............................................................................................................................136 GENERAL.............................................................................................................................136 DESCRIPTION.........................................................................................................................136 REPAIRS.................................................................................................................................138 REMOVAL OF THE DRIVE AXLE...........................................................................................................138 Disassembly of the Drive Axle...................................................................................................139 Disassembly of the Transmission and Differential................................................................................140 CLEANING............................................................................................................................142 INSPECTION..........................................................................................................................142 ASSEMBLY............................................................................................................................142 Assembly Of The Transmission And Differential...................................................................................142 Assembly Of The Drive Axle......................................................................................................148 INSTALLATION OF THE DRIVE AXLE ASSEMBLY.............................................................................................149 TROUBLESHOOTING.........................................................................................................................150 TORQUE SPECIFICATIONS...................................................................................................................151 Drive Axle Speed Reducer Differential (J40-65XM-2)..........................................................................................152 INTRODUCTION............................................................................................................................152 GENERAL.............................................................................................................................152 DESCRIPTION.........................................................................................................................152 REPAIRS.................................................................................................................................152 REMOVAL.............................................................................................................................152 DISASSEMBLY.........................................................................................................................154 CLEANING............................................................................................................................156 INSPECTION..........................................................................................................................156 ASSEMBLY............................................................................................................................156 INSTALLATION........................................................................................................................159 TROUBLESHOOTING.........................................................................................................................160 TORQUE SPECIFICATIONS...................................................................................................................160 Electrical System...........................................................................................................................162 ELECTRICAL SYSTEM.......................................................................................................................162 GENERAL.............................................................................................................................162 "LX" SERIES DISPLAY PANEL...........................................................................................................163 Hourmeter Functions.............................................................................................................164 Battery Indicator Function......................................................................................................164 Status Code Function............................................................................................................165 "ZX" SERIES DISPLAY PANELS..........................................................................................................165 Display Panel...................................................................................................................165 Basic Display Panels............................................................................................................165 Performance Display.............................................................................................................167 Brush Wear Indicators...........................................................................................................170 SEM DISPLAY PANELS - FEATURES.......................................................................................................170 Description Of Common Features..................................................................................................171 LED SYMBOL INDICATORS...........................................................................................................171 LCD SCREEN......................................................................................................................171 BATTERY DISCHARGE INDICATOR (BDI)...............................................................................................171 SERVICE REMINDER................................................................................................................171 STATUS CODES....................................................................................................................171 HOURMETER.......................................................................................................................171 Additional Features Of Premium Display Panel ...................................................................................171 Descriptions Of Additional Features (Available With The Premium Display) .......................................................172 LCD SCREEN......................................................................................................................172 OPERATOR PASSWORDS..............................................................................................................172 DAILY CHECK LIST AND SERVICE ITEMS..............................................................................................172 PERFORMANCE MODELS..............................................................................................................172 STATUS CODE LISTS...............................................................................................................172 ADJUSTMENTS OF BDI..............................................................................................................173 SEM DISPLAY PANEL INDICATORS........................................................................................................173 All Indicator Symbols...........................................................................................................173 Hourmeter Indicator Symbol......................................................................................................174 Wrench Indicator Symbol.........................................................................................................174 Battery Indicator Symbol........................................................................................................174 Battery State-Of-Charge (BDI)...................................................................................................174 Brake Fluid Too Low Symbol......................................................................................................174 Parking Brake Symbol............................................................................................................174 Fasten Seat Belt Symbol.........................................................................................................174 LCD "Screen" (Standard Display Panel)...........................................................................................174 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM.............................................................................174 Alpha Numeric "Screen"..........................................................................................................174 "Star" Push Button..............................................................................................................175 Push Buttons #1 Through #5......................................................................................................175 OTHER CONTROL COMPONENTS............................................................................................................175 REPLACEMENT.............................................................................................................................176 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"............................................................................................176 Replace The Display Panel Assembly..............................................................................................176 Replace The Key Switch..........................................................................................................177 Indicator LEDs..................................................................................................................177 Battery Indicators..............................................................................................................177 Digital Display (Performance Display Panel Only) ...............................................................................177 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only)....................................179 Replace Parts Of The Basic Display Panel .......................................................................................179 Replace Parts Of The Performance Display Panel..................................................................................180 SEM DISPLAY PANEL...................................................................................................................181 Removal And Replacement.........................................................................................................181 REPLACE MOTOR CONTROLLER (SR or SP).................................................................................................181 OTHER CONTROL COMPONENTS............................................................................................................181 Start Swtich....................................................................................................................181 Brake Light Switch..............................................................................................................182 Seat Switch.....................................................................................................................183 Adjust The External Seat Switch.................................................................................................184 Switch For Optional Seat Brake..................................................................................................184 Parking Brake Switch............................................................................................................184 Direction Switches (Monotrol Pedal)............................................................................................185 Direction Control Switches (Steering Column)....................................................................................186 Direction Control Switches, E70-120XL3 (Steering Column)........................................................................187 Brake Fluid Switch..............................................................................................................187 Brush Wear And Over Temperature Sensors.........................................................................................187 Rocker Switches For Lights .....................................................................................................188 Accelerator Position Sensor.....................................................................................................188 On-Demand Steering Components...................................................................................................190 Lights, Converter, Relay And Reverse Alarm......................................................................................192 Horn And Horn Buttons...........................................................................................................195 Hydraulic Pump Switches.........................................................................................................196 CHECKS AND ADJUSTMENTS..................................................................................................................196 GENERAL.............................................................................................................................196 CONTROL AND POWER FUSES - "LX" OR "ZX"..............................................................................................196 CONTROL AND POWER FUSES - SEM.......................................................................................................199 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"........................................................................202 THERMAL SENSORS - SEM...............................................................................................................202 ADJUST THE START SWITCH.............................................................................................................202 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3...............................................................203 Direction Switches (MONOTROL)...................................................................................................205 ADJUST THE BRAKE LIGHT SWITCH...................................................................................................205 CHECK SEAT SWITCH...............................................................................................................205 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE.......................................................................................205 ADJUST THE PARKING BRAKE SWITCH.................................................................................................206 DIRECTIONAL SWITCHES............................................................................................................206 DIRECTIONAL SWITCHES (STEERING COLUMN)..........................................................................................206 HYDRAULIC PUMP SWITCHES.........................................................................................................206 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT..................................................................................206 ADJUST THE ACCELERATOR POSITION SENSOR..........................................................................................207 Frame (E45-65XM₂)...........................................................................................................................209 INTRODUCTION............................................................................................................................209 GENERAL.............................................................................................................................209 DESCRIPTION.........................................................................................................................209 Main Frame......................................................................................................................209 Other Frame Weldments...........................................................................................................209 Battery Restraint/Hood Frame And Plate For Optional Seat Brake..................................................................211 Overhead Guard..................................................................................................................212 REPAIRS.................................................................................................................................213 OVERHEAD GUARD......................................................................................................................213 Removal.........................................................................................................................213 Installation....................................................................................................................213 BATTERY RESTRAINT AND SEAT ASSEMBLY.................................................................................................213 COUNTERWEIGHT.......................................................................................................................214 Removal.........................................................................................................................214 Installation....................................................................................................................215 TRACTION MOTOR......................................................................................................................215 Removal.........................................................................................................................215 Installation....................................................................................................................217 HYDRAULIC TANK......................................................................................................................217 Inspection......................................................................................................................217 Repairs, Small Leaks............................................................................................................217 Repairs, Large Leaks............................................................................................................218 Cleaning........................................................................................................................218 Steam Method Of Cleaning........................................................................................................218 Chemical Solution Method Of Cleaning............................................................................................218 Additional Preparations For Repair..............................................................................................219 PAINTING INSTRUCTIONS...............................................................................................................220 LABEL REPLACEMENT...................................................................................................................221 Frame (J40-65XM₂)...........................................................................................................................223 INTRODUCTION............................................................................................................................223 GENERAL ............................................................................................................................223 DESCRIPTION.........................................................................................................................223 Main Frame......................................................................................................................223 Other Frame Weldments...........................................................................................................223 Battery Restraint/Hood Frame....................................................................................................223 Overhead Guard..................................................................................................................229 REPAIRS.................................................................................................................................229 OVERHEAD GUARD......................................................................................................................229 Removal.........................................................................................................................229 Installation....................................................................................................................229 BATTERY RESTRAINT AND SEAT ASSEMBLY.................................................................................................229 Removal.........................................................................................................................229 COUNTERWEIGHT.......................................................................................................................230 Counterweight Removal...........................................................................................................230 Counterweight Installation......................................................................................................231 TRACTION MOTOR......................................................................................................................231 Motor Removal...................................................................................................................231 Motor Installation..............................................................................................................232 HYDRAULIC TANK......................................................................................................................233 Tank Removal....................................................................................................................233 Tank Inspection.................................................................................................................233 Tank Repairs, Small Leaks.......................................................................................................233 Tank Repairs, Large Leaks.......................................................................................................233 Tank Cleaning...................................................................................................................234 Steam Method Of Cleaning Tank...................................................................................................234 Chemical Solution Method Of Cleaning Tank.......................................................................................234 Additional Preparations For Tank Repair.........................................................................................234 Tank Installation (See FIGURE 10.)..............................................................................................235 PAINTING INSTRUCTIONS...............................................................................................................236 LABEL REPLACEMENT...................................................................................................................236 Global Mast Description.....................................................................................................................240 INTRODUCTION............................................................................................................................240 GENERAL.............................................................................................................................240 DESCRIPTION AND OPERATION...........................................................................................................240 Carriages.......................................................................................................................240 Mast Mounts.....................................................................................................................241 TWO-STAGE MAST, LIMITED FREE-LIFT...................................................................................................242 Description and Operation.......................................................................................................242 TWO-STAGE MAST, FULL FREE-LIFT......................................................................................................244 Description.....................................................................................................................244 Operation.......................................................................................................................244 THREE-STAGE, FULL FREE-LIFT MAST....................................................................................................246 Description.....................................................................................................................246 Operation.......................................................................................................................246 Global Mast Repair..........................................................................................................................248 INTRODUCTION ...........................................................................................................................248 GENERAL ............................................................................................................................248 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ...........................................................................................248 REPAIRS ................................................................................................................................249 FORKS ..............................................................................................................................249 Removal ........................................................................................................................249 Installation ...................................................................................................................250 CARRIAGES ..........................................................................................................................250 Removal, Standard Carriage .....................................................................................................250 Removal, Side–Shift Carriage ...................................................................................................251 Repairs ........................................................................................................................251 Installation, Standard Carriage ................................................................................................251 Installation, Side–Shift Carriage ..............................................................................................252 MAST ...............................................................................................................................253 Removal ........................................................................................................................253 Disassembly, Three–Stage FFL Mast ..............................................................................................259 Disassembly, Two–Stage LFL And Two–Stage FFL Masts .............................................................................253 Cleaning and Inspection ........................................................................................................259 Assembly, Two–Stage LFL And Two–Stage FFL Mast .................................................................................262 Assembly, Three–Stage FFL Mast .................................................................................................263 Installation, Mast .............................................................................................................264 LIFT CYLINDERS .....................................................................................................................265 Removal, Main Lift Cylinders ...................................................................................................265 Removal, Free–Lift Cylinder ....................................................................................................265 Disassembly, Lift Cylinders ....................................................................................................265 Assembly, Lift Cylinders .......................................................................................................266 Installation, Main Lift Cylinders ..............................................................................................267 Installation, Free–Lift Cylinder ...............................................................................................268 HEADER HOSE ARRANGEMENTS H/S/E/J2.00–3.20XM (H/S/E/J40–65XM) S/E/J2.00–3.00XL (S/E/J40–60XL) .......................................269 New Hose Installation, Two–Stage, LFL Mast .....................................................................................269 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .....................................................................269 New Hose Installation, Two–Stage FFL Mast ......................................................................................273 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .....................................................................273 New Hose Installation, Three–Stage FFL Mast ....................................................................................277 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ..................................................................282 HEADER HOSE ARRANGEMENTS H/E1.50–1.75XM, H/S2.00XMS (H/S/E25–35XM, H/S/E40XMS) and J1.60–2.00XMT (J30–40XMT) .......................284 New Hose Installation, Two–Stage LFL Mast ......................................................................................285 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .....................................................................285 New Hose Installation, Two–Stage FFL Mast ......................................................................................288 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .....................................................................288 New Hose Installation, Three–Stage, FFL Mast ...................................................................................292 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ..................................................................297 CHECKS AND ADJUSTMENTS .................................................................................................................298 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM .......................................................................................298 Check The Lift Cylinders For Leaks ............................................................................................298 Check The Tilt Cylinders For Leaks ............................................................................................298 ADJUST THE TILT CYLINDERS .........................................................................................................298 ADJUST THE LIFT CHAINS ............................................................................................................299 ADJUST THE MAST ...................................................................................................................300 ADJUST THE CARRIAGE ...............................................................................................................301 TROUBLESHOOTING.........................................................................................................................302 Hydraulic System............................................................................................................................303 INTRODUCTION............................................................................................................................303 GENERAL.............................................................................................................................303 DESCRIPTION.........................................................................................................................304 Hydraulic System................................................................................................................304 OPERATION...........................................................................................................................304 Hydraulic System................................................................................................................304 Hydraulic Gear Pump.............................................................................................................305 Rotator Actuator Valve..........................................................................................................305 Steering Pump...................................................................................................................308 REPAIRS.................................................................................................................................312 HYDRAULIC TANK......................................................................................................................312 E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal.................................................................................312 J2.00-3.20XM (J40-65XM) Tank Removal............................................................................................312 Tank Inspection.................................................................................................................312 Tank Repairs, Small Leaks.......................................................................................................313 Tank Repairs, Large Leaks ......................................................................................................313 Tank Cleaning...................................................................................................................313 Steam Method Of Cleaning Tank...................................................................................................313 Chemical Solution Method Of Cleaning Tank.......................................................................................313 Additional Preparations For Tank repair.........................................................................................314 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation............................................................................314 J2.00-3.20XM (J40-65XM) Tank Installation.......................................................................................314 FILTER REPLACEMENT..................................................................................................................315 HYDRAULIC PUMP......................................................................................................................315 Removing E1.50-3.20XM (E25-65XM) and N30XMH Hydraulic Pump......................................................................315 Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump...............................................................................316 Pump Seal Replacement And Pump Assembly.........................................................................................316 Assemble Pump On The Motor......................................................................................................318 Install The Hydraulic Pump And Motor Assembly [E1.50-3.20XM (E25-65XM) and N30XMH]..............................................319 Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly...............................................................319 MAIN CONTROL VALVE..................................................................................................................320 STEERING PUMP.......................................................................................................................320 Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N30XMH................................................................320 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM)...........................................................................321 Pump Assembly And Installation..................................................................................................322 ROTARY ACTUATOR VALVE...............................................................................................................323 Disassembly, Cleaning and Inspection............................................................................................323 Assembly........................................................................................................................323 STEERING CONTROL UNIT...............................................................................................................323 Control Unit Removal............................................................................................................324 Control Unit Installation.......................................................................................................324 STEERING CYLINDER...................................................................................................................324 CHECKS AND ADJUSTMENTS..................................................................................................................326 MAIN CONTROL VALVE..................................................................................................................326 STEERING RELIEF VALVE...............................................................................................................326 TROUBLESHOOTING CHART...................................................................................................................326 SPECIFICATIONS..........................................................................................................................330 Industrial Battery..........................................................................................................................333 INTRODUCTION............................................................................................................................333 GENERAL.............................................................................................................................333 LEAD-ACID BATTERIES.................................................................................................................333 SPECIFIC GRAVITY....................................................................................................................334 CHEMICAL REACTION IN A CELL.........................................................................................................334 ELECTRICAL TERMS....................................................................................................................335 HOW TO SELECT THE BATTERY...........................................................................................................335 VOLTAGE OF A BATTERY................................................................................................................335 THE BATTERY AS A COUNTERWEIGHT......................................................................................................336 BATTERY RATINGS.....................................................................................................................336 Kilowatt-Hours..................................................................................................................337 BATTERY MAINTENANCE.....................................................................................................................337 SAFETY PROCEDURES...................................................................................................................337 MAINTENCE RECORDS...................................................................................................................338 THE NEW BATTERY.....................................................................................................................338 HOW TO CLEAN THE BATTERY............................................................................................................339 HOW TO ADD WATER....................................................................................................................339 THE HYDROMETER......................................................................................................................340 BATTERY TEMPERATURE.................................................................................................................340 CHARGING THE BATTERY................................................................................................................341 Types Of Battery Charges........................................................................................................342 Methods Of Charging.............................................................................................................343 Troubleshooting The Charger.....................................................................................................343 How to Know When The Battery Is Fully Charged...................................................................................344 WHERE TO CHARGE THE BATTERIES.......................................................................................................344 Equipment Needed................................................................................................................344 BATTERY CONNECTORS..................................................................................................................345 BATTERY CARE........................................................................................................................345 Instrument Clusters.........................................................................................................................347 INTRODUCTION............................................................................................................................347 GENERAL.............................................................................................................................347 DESCRIPTION.........................................................................................................................347 REPAIRS.................................................................................................................................351 REMOVAL AND DISASSEMBLY.............................................................................................................351 ASSEMBLY AND INSTALLATION...........................................................................................................351 Main Control Valve..........................................................................................................................354 INTRODUCTION............................................................................................................................354 GENERAL.............................................................................................................................354 DESCRIPTION.........................................................................................................................354 OPERATION...........................................................................................................................355 E1.50-3.20XM (E25-65XM).........................................................................................................356 J2.00-3.20XM (J40-65XM).........................................................................................................356 Lift Section....................................................................................................................356 Tilt Section....................................................................................................................357 Relief Valve....................................................................................................................359 REPAIRS.................................................................................................................................360 MAIN CONTROL VALVE..................................................................................................................360 Removal.........................................................................................................................360 Disassembly.....................................................................................................................360 Cleaning And Inspection.........................................................................................................360 Assembly........................................................................................................................360 Installation, E1.50-3.20XM (E25-65XM)...........................................................................................362 Installation, J2.00-3.20XM (J40-65XM)...........................................................................................364 CONTROL LEVER LINKAGE, E1.50-3.20XM (E25-65XM)......................................................................................365 Removal.........................................................................................................................365 Disassembly.....................................................................................................................366 Assembly And Installation.......................................................................................................366 CONTROL VALVE LINKAGE, E1.50-3.20XM (E25-65XM)......................................................................................366 Removal And Disassembly.........................................................................................................366 Assembly And Installation.......................................................................................................367 CONTROL LEVER LINKAGE, J2.00-3.20XM (J40-65XM)......................................................................................367 Removal.........................................................................................................................367 Disassembly.....................................................................................................................367 Assembly And Installation.......................................................................................................369 CHECKS AND ADJUSTMENTS..................................................................................................................370 PRESSURE RELIEF VALVES..............................................................................................................370 Primary Relief Valve............................................................................................................370 Secondary Relief Valve..........................................................................................................370 TROUBLESHOOTING.........................................................................................................................371 Periodic Maintenance........................................................................................................................373 INTRODUCTION............................................................................................................................373 GENERAL.............................................................................................................................373 SERIAL NUMBER DATA..................................................................................................................373 HOW TO MOVE A DISABLED LIFT TRUCK...................................................................................................373 How To Tow A Lift Truck ........................................................................................................373 HOW TO PUT A LIFT TRUCK ON BLOCKS...................................................................................................374 How To Raise The Drive Tires....................................................................................................374 How To Raise The Steering Tires.................................................................................................374 MAINTENANCE SCHEDULE....................................................................................................................375 MAINTENANCE PROCEDURES..................................................................................................................378 EVERY 8 HOURS OR DAILY..................................................................................................................378 Tires And Wheels....................................................................................................................378 Forks...............................................................................................................................379 Fork Adjustment.....................................................................................................................379 Fork Removal........................................................................................................................379 Fork Installation...................................................................................................................380 Inspection Of Forks, Mast And Lift Chains...........................................................................................380 Safety Labels.......................................................................................................................381 Steering Column Latch...............................................................................................................381 Operator Restraint System...........................................................................................................382 Battery Restraint System, E25-65XM, E25-65XM2......................................................................................382 Battery Restraint System - J40-65XM-65XM, J40-65XM2................................................................................383 Battery.............................................................................................................................383 Hydraulic System....................................................................................................................384 HOW TO MAKE CHECKS WITH THE KEY "ON"................................................................................................385 Gauges, Horn And Fuses..........................................................................................................385 Steering System.................................................................................................................385 Service Brake...................................................................................................................385 Parking Brake...................................................................................................................386 Control Levers And Pedals.......................................................................................................386 Lift System Operation...........................................................................................................386 EVERY 350 HOURS OR THREE MONTHS ........................................................................................................387 HYDRAULIC TANK BREATHER.............................................................................................................387 DIFFERENTIAL AND SPEED REDUCER......................................................................................................387 WHEEL NUT TORQUES...................................................................................................................388 STEERING AXLE SPINDLES..............................................................................................................388 MAST................................................................................................................................388 LIFT CHAINS.........................................................................................................................389 Check For Wear..................................................................................................................389 Lubrication.....................................................................................................................389 FORKS...............................................................................................................................389 BRAKE FLUID.........................................................................................................................390 OTHER LUBRICATION...................................................................................................................390 SEAT BRAKE (E25-65XM, E25-65XM2 Only................................................................................................390 ELECTRICAL INSPECTION...............................................................................................................390 Contactors......................................................................................................................391 Motor Brushes...................................................................................................................391 Motor Brushes, General..........................................................................................................391 EVERY 2000 HOURS OR YEARLY..............................................................................................................401 HYDRAULIC SYSTEM....................................................................................................................401 Change The Filter For The Hydraulic Oil.........................................................................................401 Change The Hydraulic Oil........................................................................................................402 DIFFERENTIAL AND SPEED REDUCER......................................................................................................402 SERVICE BRAKES......................................................................................................................402 CONTACTORS..........................................................................................................................403 WHEEL BEARINGS......................................................................................................................403 Steer Wheels, Lubrication.......................................................................................................403 Drive Wheels, Lubrication.......................................................................................................403 LIFT CHAINS.........................................................................................................................403 GENERAL PROCEDURE.......................................................................................................................403 HOW TO CHARGE THE BATTERY...........................................................................................................403 HOW TO CHANGE THE BATTERY...........................................................................................................405 General.........................................................................................................................405 Change The E25-65XM, E25-65XM2 Battery..........................................................................................405 Change The J40-65XM, J40-65XM2 Battery..........................................................................................407 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.........................................................................................409 Check The Lift Cylinders For Leaks..............................................................................................409 Check The Tilt Cylinders For Leaks..............................................................................................409 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)...............................................................................410 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)...............................................................................411 LIFT CHAIN ADJUSTMENTS..............................................................................................................411 HOW TO CHECK THE PMT CIRCUIT........................................................................................................412 WELDING REPAIRS.....................................................................................................................413 CHANGES TO THE OVERHEAD GUARD.......................................................................................................413 TIRES AND WHEELS, E25-65XM, E25-65XM2...............................................................................................413 Remove The Wheels From The Lift Truck..........................................................................................414 Remove And Install The Tire On The Wheel........................................................................................414 PNEUMATIC TIRES AND WHEELS J40-65XM, J40-65XM2......................................................................................414 Remove The Wheels From The Lift Truck...........................................................................................414 Remove The Wheel From The Pneumatic Tire........................................................................................415 Install The Wheel In The Pneumatic Tire.........................................................................................416 Add Air To The Tires............................................................................................................417 Install The Wheels..............................................................................................................417 SOLID RUBBER TIRES ON PNEUMATIC WHEELS..............................................................................................417 Remove The Wheels From The Lift Truck...........................................................................................417 Remove The Solid Rubber Tire From The Pneumatic Wheel...........................................................................417 Install The Solid Rubber Tire On The Pneumatic Wheel............................................................................419 Install The Wheels .............................................................................................................419 REFERENCE TABLE.........................................................................................................................420 Adhesive And Sealants ..............................................................................................................420 SAE & Metric Fasteners......................................................................................................................421 INTRODUCTION............................................................................................................................421 NOMENCLATURE, THREADS...............................................................................................................421 STRENGTH IDENTIFICATION.............................................................................................................422 TABLE 1. BOLTS AND SCREWS...............................................................................................................422 TABLE 2. STUDS AND NUTS.................................................................................................................423 TABLE 3. TORQUE NUTS....................................................................................................................424 TABLE 4. TORQUE NUTS WITH NYLON INSERT..................................................................................................425 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...............................................................................................426 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.............................................................................................427 SEM Display Panel...........................................................................................................................430 SEM DISPLAY PANEL.......................................................................................................................430 GENERAL.............................................................................................................................430 SEM DISPLAY PANEL FEATURES..........................................................................................................430 Description Of Common Features..................................................................................................430 LED SYMBOL INDICATORS...........................................................................................................430 LED SCREEN .....................................................................................................................430 BATTERY DISCHARGE INDICATOR (BDI)...............................................................................................430 SERVCE REMINDER.................................................................................................................431 STATUS CODES....................................................................................................................431 HOURMETER.......................................................................................................................431 Additional Features Of Premium Display Panel....................................................................................431 Descriptions Of Additional Features (Available With The Premium Display)........................................................431 LCD SCREEN......................................................................................................................431 OPERATOR PASSWORDS..............................................................................................................431 DAILY CHECK LIST AND SERVICE ITEMS..............................................................................................432 PERFORMANCE MODES...............................................................................................................432 STATUS CODES LIST...............................................................................................................432 ADJUSTMENT OF BDI...............................................................................................................433 SEM DISPLAY PANEL INDICATORS........................................................................................................433 All Indicator Symbols...........................................................................................................433 Hourmeter Indicator Symbol......................................................................................................434 Wrench Indicator Symbol.........................................................................................................434 Battery Indicator Symbol........................................................................................................434 Battery State-Of-Charge (BDI)...................................................................................................434 Brake Fluid Too Low Symbol......................................................................................................434 Parking Brake Symbol............................................................................................................434 Fasten Seat Belt Symbol.........................................................................................................434 LCD Screen (Standard Display Panel).............................................................................................434 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL..................................................................................434 Alpha Numeric Screen............................................................................................................434 "STAR" Push Button..............................................................................................................435 Push Buttons #1 Through #5......................................................................................................435 ADJUSTMENTS WITH A COMPUTER.........................................................................................................436 COMPUTER SYSTEM.................................................................................................................436 Connect A PC To The SEM Display Panel...........................................................................................436 ITW SWITCHES SOFTWARE PROGRAM (For SEM Display Panel)...........................................................................437 Description.................................................................................................................437 Where To Get Help...........................................................................................................437 Hardware And Software Requirements..........................................................................................437 How To Start The ITW SWITCHES Program.......................................................................................438 Menus.......................................................................................................................438 Create A Setup File.........................................................................................................446 REPLACEMENT.........................................................................................................................466 GENERAL.........................................................................................................................466 SEM DISPLAY PANEL...............................................................................................................466 Removal And Replacement ........................................................................................................466 SR-SP Motor Controller Description & Operation..............................................................................................469 TRANSISTOR MOTOR CONTROLLERS (SR AND SP) DESCRIPTION, CHECKS & ADJUSTMENTS, TROUBLESHOOTING, REPAIRS, AND THEORY OF OPERATION...........469 DESCRIPTION.........................................................................................................................469 General.........................................................................................................................469 Model Number Data For Transistor Motor Controllers (SR and SP)..................................................................470 MOTOR CONTROLLER, CHECKS AND ADJUSTMENTS............................................................................................472 CHECKS AND ADJUSTMENTS USING A HAND SET.............................................................................................473 General.........................................................................................................................473 Connect Hand Set................................................................................................................474 Start Sequence..................................................................................................................474 Check Or Delete Stored Status Codes.............................................................................................474 Returning The Lift Truck To Normal Operation....................................................................................475 Checks And Adustments On The Work Bench.........................................................................................475 How To Check And Adjust The Registers...........................................................................................477 ADJUSTMENTS - FUNCTION PARAMETERS...................................................................................................478 General.........................................................................................................................478 Function Numbers................................................................................................................478 When The Hand Set Is Connected To A Motor Controller In The Lift Truck..........................................................479 FUNCTION NUMBER DESCRIPTIONS........................................................................................................480 TRACTION MOTOR CONTROLLER (LABEL LETTER - SR).......................................................................................480 FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY...........................................................................................485 PUMP MOTOR CONTROLLER (LABEL LETTER - SP)...........................................................................................487 FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY...........................................................................................490 TROUBLESHOOTING - STATUS CODE CHARTS....................................................................................................495 TROUBLESHOOTING.....................................................................................................................496 General.........................................................................................................................496 Status Codes....................................................................................................................496 REPAIRS.................................................................................................................................524 GENERAL.............................................................................................................................524 GENERAL MAINTENANCE INSTRUCTIONS....................................................................................................524 Special Precautions.............................................................................................................524 FUSES...............................................................................................................................527 CONTACTORS..........................................................................................................................527 Contactor Repair................................................................................................................527 CONTACTOR DRIVER MODULE.............................................................................................................529 Replace Contactor Driver........................................................................................................529 MOTOR CONTROLLER PLUG...............................................................................................................529 BRUSH WEAR INDICATORS...............................................................................................................529 THERMAL SENSORS.....................................................................................................................530 REPLACE MOTOR CONTROLLER............................................................................................................530 THEORY OF OPERATION.....................................................................................................................535 GENERAL.............................................................................................................................535 DESCRIPTION OF SEM SYSTEM...........................................................................................................535 OPERATION OF SEM SYSTEM (SR MOTOR CONTROLLER).......................................................................................536 Reverse Circuit.................................................................................................................536 Performance and Efficiency......................................................................................................536 Field Weakening.................................................................................................................537 Regenerative Braking............................................................................................................537 INTRODUCTION........................................................................................................................537 General.........................................................................................................................537 Creep Speed.....................................................................................................................537 Controlled Acceleration.........................................................................................................537 Current Limit...................................................................................................................538 BRAKING.............................................................................................................................538 Regenerative Braking to Zero Speed..............................................................................................538 Pedal Position Braking..........................................................................................................538 Auto Braking....................................................................................................................538 AUXILIARY SPEED CONTROL.............................................................................................................538 Field Weakening.................................................................................................................538 Speed Limits....................................................................................................................539 RAMP OPERATION......................................................................................................................539 Ramp Start......................................................................................................................539 Anti-Rollback...................................................................................................................539 STEER PUMP CONTACTOR TIME DELAY.....................................................................................................539 COIL DRIVERS AND INTERNAL COIL SUPPRESSION..........................................................................................539 SYSTEM PROTECTIVE OVERRIDE..........................................................................................................539 SRO (Static Return to Off)......................................................................................................539 Accelerator Volts Hold Off......................................................................................................539 Pulse Monitor Trip (PMT)........................................................................................................539 Thermal Protector (TP)..........................................................................................................540 Low Voltage.....................................................................................................................540 SP PUMP MOTOR CONTROLLERS...........................................................................................................540 CONTACTOR DRIVER MODULE.............................................................................................................540 DIAGNOSTICS.........................................................................................................................541 System Diagnostics..............................................................................................................541 Standard Status Codes...........................................................................................................541 Stored Status Codes.............................................................................................................541 Hourmeter Readings..............................................................................................................541 Maintenance Management Capability...............................................................................................541 SR-SP Motor Controller Parameter Tables.....................................................................................................547 SR (SEM) AND SP TRANSISTOR MOTOR CONTROLLER,Parameter Tables............................................................................547 GENERAL.............................................................................................................................547 Function Numbers...............................................................................................................547 MOTOR CONTROLLER CHECKS AND ADJUSTMENTS.............................................................................................548 TABLE 1.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V) (Standard Speed Motor With EE ....549 Parameter Tables................................................................................................................548 TABLE 2.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V) (High Speed Motor With E or ES....551 TABLE 3.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - E25-40XM2 (D114) (36 to 48V).............................................553 TABLE 4.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E45-65XM2 (F108) (36 to 48V) (9 Inch Traction Motor)...........555 TABLE 5.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - E45-65XM2 (F108) (36 to 48V) (11 Inch Traction Motor)..........558 TABLE 6.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER -E45-65XM2 (F108) (36 to 48V)..............................................561 TABLE 7.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER -J45-65XM2 (A216) (36 to 48V) (E OR ES RATED)....................563 TABLE 8.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER -J45-65XM2 (A216) (36 to 48V) (EE RATED).........................565 TABLE 9.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - J45-65XM2 (A216) (36 to 48V).............................................567 TABLE 10.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V) (9 INCH MOTOR).....................569 TABLE 11.SR (SEM) REGISTER PARAMETERS FOR TRACTION MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V) (11 INCH MOTOR)....................572 TABLE 12.SP REGISTER PARAMETERS FOR PUMP MOTOR CONTROLLER - N30XMH2 (C210) (36 to 48V)..............................................575 SR-SP Troubleshooting & Adjustments.........................................................................................................577 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers................................577 COMPUTER SYSTEM.....................................................................................................................577 Connect A PC To A Control Card..................................................................................................578 HYTECt SOFTWARE PROGRAM ............................................................................................................579 How To Start The Program........................................................................................................579 Selecting The Communications Port...............................................................................................580 Verification Of Controller and Lift Truck.......................................................................................580 Select The Lift Truck Series....................................................................................................581 Undefined Controller Card.......................................................................................................582 Controller Card Register Parameter List.........................................................................................582 How To Enter A New Parameter....................................................................................................583 How To Save A Changed Parameter File............................................................................................584 How To Load A Saved Parameter File..............................................................................................584 How To Return To Factory Default Settings.......................................................................................585 How To Save Changes To The Controller Card......................................................................................586 How To View The Status Codes ...................................................................................................586 Saving The Status Code To Disk..................................................................................................587 Closing and Clearing The Status Code List.......................................................................................588 COMMUNICATIONS PROGRAM (MODEM)......................................................................................................588 Requirements....................................................................................................................589 README File.....................................................................................................................590 GE Sentry Software..................................................................................................................590 Getting Started.................................................................................................................590 Where To Get Help...............................................................................................................591 Hardware and Software Requirements..............................................................................................591 Installation of the GE SENTRY SOFTWARE..........................................................................................591 How To Start The GE SENTRY Program..............................................................................................591 How To Reset The MIN and MAX Display............................................................................................593 How To Exit The GE SENTRY Program...............................................................................................593 Steering Axle (E45-65XM₂)...................................................................................................................594 INTRODUCTION............................................................................................................................594 GENERAL.............................................................................................................................594 DESCRIPTION.........................................................................................................................594 REPAIRS.................................................................................................................................595 STEERING AXLE ASSEMBLY..............................................................................................................595 Removal.........................................................................................................................595 Installation....................................................................................................................595 WHEELS..............................................................................................................................595 Removal And Disassembly.........................................................................................................595 Cleaning........................................................................................................................595 Assembly And Installation.......................................................................................................596 SPINDLES, BEARINGS, AND TIE RODS....................................................................................................596 Removal And Disassembly.........................................................................................................596 Assembly And Installation.......................................................................................................597 STEERING CYLINDER...................................................................................................................598 Removal And Disassembly.........................................................................................................598 Cleaning And Inspection.........................................................................................................598 Assembly And Installation.......................................................................................................598 TROUBLESHOOTING.........................................................................................................................599 TORQUE SPECIFICATIONS...................................................................................................................599 Steering Axle (J40-65XM₂)...................................................................................................................601 STEERING SYSTEM.........................................................................................................................601 GENERAL.............................................................................................................................601 DESCRIPTION.........................................................................................................................603 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................................................604 Removal Of The Assembly Components..............................................................................................604 Installation Of The Assembly Components.........................................................................................608 POWER STEERING MOTOR AND PUMP...........................................................................................................609 DESCRIPTION.........................................................................................................................609 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)..................................609 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3).......................................................................609 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)....................................................................................610 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)...................................................................................612 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)..................................................................................613 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]......................................613 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)..................................................................................614 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)................................................................................616 REPAIRS, POWER STEERING PUMP........................................................................................................617 Seal Replacement................................................................................................................618 HYDRAULIC STEERING MOTOR................................................................................................................618 DESCRIPTION.........................................................................................................................618 REPAIRS, HYDRAULIC STEERING MOTOR...................................................................................................619 Removal ........................................................................................................................619 Disassembly.....................................................................................................................619 Cleaning And Inspection.........................................................................................................619 Assembly........................................................................................................................620 Installation, Hydraulic Steering Motor..........................................................................................621 CHECKS AND ADJUSTMENTS..................................................................................................................621 AIR IN THE STEERING SYSTEM..........................................................................................................621 CHECK STEERING PRESSURE.............................................................................................................621 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only).......................................................................622 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS.......................................................................................623 TROUBLESHOOTING.........................................................................................................................625 Steering Housing & Control Unit.............................................................................................................628 INTRODUCTION............................................................................................................................628 GENERAL.............................................................................................................................628 DESCRIPTION.........................................................................................................................628 OPERATION...........................................................................................................................628 REPAIRS.................................................................................................................................629 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................................................629 Removal of the Assembly Components..............................................................................................633 Disassembly of the Steering Control Unit........................................................................................634 Cleaning of the Steering Control Unit...........................................................................................634 Assembly of the Steering Control Unit...........................................................................................634 Installation of the Steering Control Unit.......................................................................................634 Installation of the Assembly Components.........................................................................................634 CHECKS AND ADJUSTMENTS..................................................................................................................642 REMOVE AIR FROM THE SYSTEM..........................................................................................................642 TROUBLESHOOTING.........................................................................................................................642 Steering System.............................................................................................................................644 STEERING SYSTEM.........................................................................................................................644 GENERAL.............................................................................................................................644 DESCRIPTION.........................................................................................................................646 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................................................647 Removal Of The Assembly Components..............................................................................................647 Installation Of The Assembly Components.........................................................................................651 POWER STEERING MOTOR AND PUMP...........................................................................................................652 DESCRIPTION.........................................................................................................................652 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)..................................652 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3).......................................................................652 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)....................................................................................653 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)...................................................................................655 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)..................................................................................656 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]......................................656 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)..................................................................................657 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)................................................................................659 REPAIRS, POWER STEERING PUMP........................................................................................................660 Seal Replacement................................................................................................................661 HYDRAULIC STEERING MOTOR................................................................................................................661 DESCRIPTION.........................................................................................................................661 REPAIRS, HYDRAULIC STEERING MOTOR...................................................................................................662 Removal ........................................................................................................................662 Disassembly.....................................................................................................................662 Cleaning And Inspection.........................................................................................................662 Assembly........................................................................................................................663 Installation, Hydraulic Steering Motor..........................................................................................664 CHECKS AND ADJUSTMENTS..................................................................................................................664 AIR IN THE STEERING SYSTEM..........................................................................................................664 CHECK STEERING PRESSURE.............................................................................................................664 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only).......................................................................665 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS.......................................................................................666 TROUBLESHOOTING.........................................................................................................................668 Tilt Cylinders..............................................................................................................................671 INTRODUCTION............................................................................................................................671 GENERAL.............................................................................................................................671 DESCRIPTION.........................................................................................................................671 REPAIRS.................................................................................................................................671 REMOVAL.............................................................................................................................671 DISASSEMBLY.........................................................................................................................671 CLEANING............................................................................................................................671 ASSEMBLY............................................................................................................................671 Tilt Cylinders with O-Rings or Single Lip Seals.................................................................................671 Tilt Cylinders for the XM and XMS Models........................................................................................672 Tilt Cylinders for H700 800A and Early Model H700 920B..........................................................................674 INSTALLATION........................................................................................................................674 Tilt Cylinders Using Chevron Packing............................................................................................675 CHECKS AND ADJUSTMENTS..................................................................................................................677 CHECK THE TILT CYLINDERS FOR LEAKS..................................................................................................677 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.............................................................................677 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS................................................................................678 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS...............................................................................679 TROUBLESHOOTING.........................................................................................................................681
HYSTER F108 (E45-65XM₂, J40-65XM₂) SERVICE MANUAL – PDF DOWNLOAD:
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