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Hyster F108 (E45-65XM) Service Manual – PDF DOWNLOAD
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Description
Hyster F108 (E45-65XM) Service Manual – PDF DOWNLOAD
FILE DETAILS
Hyster F108 (E45-65XM) Service Manual – PDF DOWNLOAD
Language : English
Pages : 685
Downloadable : Yes
File Type : PDF
Size: 20 MB
TABLE OF CONTENTS:
Hyster F108 (E45-65XM) Service Manual – PDF DOWNLOAD
4 Stage Mast.................................................................................................................................... 1 INTRODUCTION................................................................................................................................ 1 GENERAL................................................................................................................................. 1 CARRIAGES............................................................................................................................... 1 MAST MOUNTS............................................................................................................................. 2 MAST.................................................................................................................................... 2 Description......................................................................................................................... 2 Operation........................................................................................................................... 3 REPAIRS..................................................................................................................................... 6 FORKS................................................................................................................................... 6 Removal............................................................................................................................. 6 Installation........................................................................................................................ 6 SAFETY PROCEUDRES WHEN WORKING NEAR THE MAST............................................................................................ 7 CARRIAGES............................................................................................................................... 8 Removal............................................................................................................................. 8 Repairs............................................................................................................................. 9 Installation........................................................................................................................ 9 MAST.................................................................................................................................... 10 Removal............................................................................................................................. 10 Disassembly......................................................................................................................... 10 Cleaning and Inspection............................................................................................................. 12 Assembly............................................................................................................................ 15 Installation........................................................................................................................ 16 LIFT CYLINDERS.......................................................................................................................... 16 Removal............................................................................................................................. 16 Disassembly......................................................................................................................... 17 Assembly............................................................................................................................ 17 Installation........................................................................................................................ 18 HEADER HOSE ARRANGEMENTS................................................................................................................ 20 Installation, Header Hoses.......................................................................................................... 20 CHECKS AND ADJUSTMENTS...................................................................................................................... 26 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM............................................................................................. 26 Check The Lift Cylinders For Leaks.................................................................................................. 26 Check The Tilt Cylinders For Leaks.................................................................................................. 27 ADJUST THE TILT CYLINDERS............................................................................................................... 27 LIFT CHAIN ADJUSTMENTS.................................................................................................................. 27 MAST ADJUSTMENTS........................................................................................................................ 28 CARRIAGE ADJUSTMENTS.................................................................................................................... 29 TROUBLESHOOTING............................................................................................................................. 31 Brake System (E45-65XM)......................................................................................................................... 32 INTRODUCTION................................................................................................................................ 32 GENERAL................................................................................................................................. 32 DESCRIPTION AND OPERATION............................................................................................................... 32 Service Brakes...................................................................................................................... 32 Master Cylinder..................................................................................................................... 32 Parking Brake....................................................................................................................... 34 SERVICE BRAKES.......................................................................................................................... 34 Removal And Disassembly............................................................................................................. 34 Cleaning............................................................................................................................ 36 Inspection.......................................................................................................................... 37 Assembly And Installation........................................................................................................... 37 Adjustments......................................................................................................................... 39 PARKING BRAKE........................................................................................................................... 39 Removal And Disassembly............................................................................................................. 39 Assembly And Installation........................................................................................................... 40 Adjust The Parking Brake............................................................................................................ 40 MASTER CYLINDER......................................................................................................................... 43 Removal............................................................................................................................. 43 Cleaning And Inspection............................................................................................................. 43 Repair.............................................................................................................................. 43 Installation........................................................................................................................ 43 SEAT BRAKE ASSEMBLY..................................................................................................................... 46 CHECKS AND ADJUSTMENTS...................................................................................................................... 47 ADJUST THE SERVICE BRAKES............................................................................................................... 47 ADJUST THE BRAKE PEDAL.................................................................................................................. 47 ADJUST THE MASTER CYLINDER.............................................................................................................. 47 REMOVE THE AIR FROM THE BRAKE SYSTEM.................................................................................................... 47 TEST THE "PARKING BRAKE NOT APPLIED" WARNING............................................................................................ 47 TROUBLESHOOTING............................................................................................................................. 48 TORQUE SPECIFICATIONS....................................................................................................................... 50 Brake System (J40-65XM)......................................................................................................................... 53 INTRODUCTION................................................................................................................................ 53 GENERAL................................................................................................................................. 53 DESCRIPTION AND OPERATION............................................................................................................... 53 Service Brakes...................................................................................................................... 53 Master Cylinder ........................................................................................................................ 53 Parking Brake....................................................................................................................... 53 SERVICE BRAKES.......................................................................................................................... 55 Removal And Disassembly............................................................................................................. 55 Cleaning............................................................................................................................ 57 Inspection.......................................................................................................................... 57 Assembly And Installation........................................................................................................... 58 Adjustments......................................................................................................................... 59 PARKING BRAKE........................................................................................................................... 61 Removal And Disassembly............................................................................................................. 61 Assembly And Installation .......................................................................................................... 61 Adjust The Parking Brake............................................................................................................ 62 MASTER CYLINDER......................................................................................................................... 65 Removal............................................................................................................................. 65 Cleaning And Inspection............................................................................................................. 65 Repair.............................................................................................................................. 65 Installation........................................................................................................................ 65 CHECKS AND ADJUSTMENTS...................................................................................................................... 67 ADJUST THE SERVICE BRAKES............................................................................................................... 67 ADJUST THE BRAKE PEDAL.................................................................................................................. 68 ADJUST THE MASTER CYLINDER.............................................................................................................. 68 REMOVE THE AIR FROM THE BRAKE SYSTEM.................................................................................................... 68 TEST THE "PARKING BRAKE NOT APPLIED" WARNING............................................................................................ 68 TROUBLESHOOTING............................................................................................................................. 69 TORQUE SPECIFICATIONS....................................................................................................................... 71 Capacities & Specification...................................................................................................................... 72 COUNTERWEIGHTS.............................................................................................................................. 72 HYDRAULIC SYSTEM............................................................................................................................ 72 WHEELS AND TIRES ........................................................................................................................... 73 BATTERY SPECIFICATIONS - E2.00-3.20XM (E45-65XM, E45-XM2, N30XMH, N30XMH2).................................................................. 73 BATTERY SPECIFICATIONS - J2.00-3.20XM (J40-65XM, J40-65XM2)................................................................................. 74 CAPACITIES.................................................................................................................................. 74 MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS................................................................................................. 74 E45-65XM MAST SPEEDS (36 or 48 Volt) Americas............................................................................................... 75 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 75 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 76 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 77 E40-65XM, E40-65XM2, N30XMH2 MAST SPEEDS (36 or 48 Volt) (3/99) Americas.................................................................... 78 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*................................................................................................ 78 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*................................................................................................ 79 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 80 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 80 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 81 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 82 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 83 CONTACTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.................................................................................. 83 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................................ 84 E2.00-3.20XM, E2.00-3.20XM2, MAST SPEEDS (72 or 80 Volt) (3/99) Europe...................................................................... 85 190 mm MOTOR & LARGE LIFT PUMP*......................................................................................................... 85 190 mm MOTOR & SMALL LIFT PUMP*......................................................................................................... 86 203 or 190 mm LONG STACK MOTOR & SMALL LIFT PUMP*....................................................................................... 87 J40-65XM MAST SPEEDS (36 or 48 Volt) Americas............................................................................................... 88 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 88 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 89 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 90 J40-65XM, J40-65XM2, MAST SPEEDS (36 or 48 Volt) (3/99) Americas............................................................................ 91 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*................................................................................................ 91 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*................................................................................................ 92 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 93 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................ 93 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 94 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*........................................................................ 95 CONT. OR TRANSISTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................ 96 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................................ 97 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) (3/99) Europe...................................................................................... 98 190 mm MOTOR & LARGE LIFT PUMP*......................................................................................................... 98 190 mm MOTOR & SMALL LIFT PUMP*......................................................................................................... 99 203 or 190 mm LONG STACK MOTOR & LARGE LIFT PUMP*.......................................................................................100 TORQUE SPECIFICATIONS.......................................................................................................................101 REFERENCE TABLE.............................................................................................................................104 DC Motor Maintenance............................................................................................................................105 INTRODUCTION................................................................................................................................105 ELECTRIC MOTOR MAINTENANCE, GENERAL.....................................................................................................105 BRUSH AND COMMUNICATOR INSPECTION.......................................................................................................105 Hydraulic Pump Motor And Traction Motor.............................................................................................105 Steering Pump Motor.................................................................................................................107 BRUSH WEAR REPLACEMENT GUIDE................................................................................................................107 Commutator Problems.....................................................................................................................109 BRUSH REPLACEMENTS......................................................................................................................111 DISASSEMBLY OF MOTORS...................................................................................................................113 Traction Motor And Hydraulic Pump Motor.............................................................................................113 Steering Pump Motor.................................................................................................................119 ASSEMBLY OF MOTORS......................................................................................................................121 Traction Motor And Hydraulic Pump Motor ............................................................................................121 Steering Pump Motor.................................................................................................................121 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS..........................................................................................121 TESTS FOR A DAMAGED FIELD AND ARMATURE..................................................................................................122 Test For An Open Circuit In The Armature............................................................................................122 Test For A Short-Circuit In One Armature Winding....................................................................................122 Test For A Short-Circuit To Armature Shaft..........................................................................................123 Test For An Open Circuit In A Field Coil............................................................................................123 Test For A Short-Circuit In A Field Coil............................................................................................123 Test For A Short-Circuit Between The Field And The Motor Case.......................................................................124 Brush Holder Test...................................................................................................................124 TROUBLESHOOTING.............................................................................................................................124 Diagrams........................................................................................................................................126 FIGURE 1. SCHEMATIC - EV - 100ZX SCR CONTROL FOR TRACTION MOTOR.............................................................................126 FIGURE 2. SCHEMATIC - EV - 100ZX SCR CONTROL FOR LIFT PUMP MOTOR............................................................................127 FIGURE 3. SCHEMATIC - CONTACTOR CONTROL FOR LIFT PUMP MOTOR.................................................................................128 FIGURE 4. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................130 FIGURE 5. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................132 FIGURE 6. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................134 FIGURE 7. WIRING CONNECTIONS, CONTROLLER PANEL-TOPANEL, E2.00-3.20XM (E45-65XM) AND N30XMH..................................................135 FIGURE 8. WIRING CONNECTIONS, CONTROLLER PANEL-TO-PANEL, J2.00-3.20XM (J40-65XM)............................................................136 FIGURE 9. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM)...........................................................................................138 FIGURE 10. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM)..........................................................................................140 FIGURE 11. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM)..........................................................................................142 FIGURE 12. TRUCK WIRING HARNESSES AND CABLES, E2.00-3.20XM (E45-65XM) AND N30XMH............................................................143 FIGURE 13. TRUCK POWER CABLES, E2.00-3.20XM (E45-65XM) AND N30XMH...........................................................................144 FIGURE 14. EV - 100 ZX SCR TRACTION AND PUMP MOTOR CONTROLLERS, E2.00-3.20XM (E45-65XM) AND N30XMH..........................................145 FIGURE 15. EV - 100 ZX SCR TRACTION MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL, E2.00-3.20XM (E45-65XM)....................................146 FIGURE 16. EV - 100ZX SCR TRACTION MOTOR AND SCR PUMP MOTOR CONTROLLERS, E2.00-3.20XM (E45-65XM) AND N30XMH.................................147 FIGURE 17. EV - 100ZX SCR TRACTION MOTOR CONTROLLER WITH CONTACTOR CONTROL OF PUMP MOTOR, E2.00-3.20XM (E45-65XM)...........................148 FIGURE 18. EV - 100ZX CONTACTOR PANEL, E2.00-3.20XM (E45-65XM) AND N30XMH...................................................................149 FIGURE 19. CHASSIS AND HYDRAULIC LINKAGE, SWITCH WIRING DETAILS, E2.00-3.20XM (E45-65XM) AND N30XMH.........................................150 FIGURE 20. TRUCK WIRING HARNESSES AND CABLES, J2.00-3.20XM (J40-65XM).......................................................................151 FIGURE 21. TRUCK POWER CANLES, J2.00-3.20XM (J40-65XM)......................................................................................152 FIGURE 22. EV - 100 ZX SCR TRACTION AND PUMP MOTOR CONTROLLERS, J2.00-3.20XM (J40-65XM).....................................................153 FIGURE 23. EV - 100 ZX SCR TRACTION MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL, J2.00-3.20XM (J40-65XM)....................................154 FIGURE 24. EV - 100ZX SCR TRACTION MOTOR AND SCR PUMP MOTOR CONTROLLERS, J2.00-3.20XM (J40-65XM)............................................155 FIGURE 25. EV - 100ZX SCR TRACTION MOTOR CONTROLLER WITH CONTACTOR CONTROL OF PUMP MOTOR, J2.00-3.20XM (J40-65XM)...........................156 FIGURE 26. EV - 100ZX CONTACTOR PANEL, J2.00-3.20XM (J40-54XM)..............................................................................157 FIGURE 27. CHASSIS AND HYDRAULIC LINKAGE, SWITCH WIRING DETAILS, J2.00-3.20XM (J40-65XM)....................................................158 FIGURE 28. STEERING COLUMN WIRING DETAIL....................................................................................................159 FIGURE 29. DISPLAY PANELS AND PLUG CONNECTORS...............................................................................................160 FIGURE 30. DETAIL OF BATTEY CONNECTORS WITH +12 VOLT TAP....................................................................................161 FIGURE 31. LIGHTING SCHEMATIC (CHASSIS).....................................................................................................162 FIGURE 32. LIGHTING SCHEMATIC (REAR), E2.00-3.02XM (E45-65XM) AND N30XMH....................................................................163 FIGURE 33. LIGHTING SCHEMATIC (REAR), J2.00-3.02XM (J40-65XM)...............................................................................164 FIGURE 34. LIGHTING WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH......................................................................166 FIGURE 35. LIGHTING WIRING DIAGRAM, J2.00-3.02XM (J40-65XM).................................................................................168 Drive Axle Speed Reducer Differential (E45-65XM)................................................................................................169 INTRODUCTION................................................................................................................................169 GENERAL.................................................................................................................................169 DESCRIPTION.............................................................................................................................169 REPAIRS.....................................................................................................................................171 REMOVAL OF THE DRIVE AXLE...............................................................................................................171 Disassembly of the Drive Axle.......................................................................................................172 Disassembly of the Transmission and Differential....................................................................................173 CLEANING................................................................................................................................175 INSPECTION..............................................................................................................................175 ASSEMBLY................................................................................................................................175 Assembly Of The Transmission And Differential.......................................................................................175 Assembly Of The Drive Axle..........................................................................................................181 INSTALLATION OF THE DRIVE AXLE ASSEMBLY.................................................................................................182 TROUBLESHOOTING.............................................................................................................................183 TORQUE SPECIFICATIONS.......................................................................................................................184 Drive Axle Speed Reducer Differential (J40-65XM)................................................................................................185 INTRODUCTION................................................................................................................................185 GENERAL.................................................................................................................................185 DESCRIPTION.............................................................................................................................185 REPAIRS.....................................................................................................................................185 REMOVAL.................................................................................................................................185 DISASSEMBLY.............................................................................................................................187 CLEANING................................................................................................................................189 INSPECTION..............................................................................................................................189 ASSEMBLY................................................................................................................................189 INSTALLATION............................................................................................................................192 TROUBLESHOOTING.............................................................................................................................193 TORQUE SPECIFICATIONS.......................................................................................................................193 Electrical System...............................................................................................................................195 ELECTRICAL SYSTEM...........................................................................................................................195 GENERAL.................................................................................................................................195 "LX" SERIES DISPLAY PANEL...............................................................................................................196 Hourmeter Functions.................................................................................................................197 Battery Indicator Function..........................................................................................................197 Status Code Function................................................................................................................198 "ZX" SERIES DISPLAY PANELS..............................................................................................................198 Display Panel.......................................................................................................................198 Basic Display Panels................................................................................................................198 Performance Display.................................................................................................................200 Brush Wear Indicators...............................................................................................................203 SEM DISPLAY PANELS - FEATURES...........................................................................................................203 Description Of Common Features......................................................................................................204 LED SYMBOL INDICATORS...............................................................................................................204 LCD SCREEN..........................................................................................................................204 BATTERY DISCHARGE INDICATOR (BDI)...................................................................................................204 SERVICE REMINDER....................................................................................................................204 STATUS CODES........................................................................................................................204 HOURMETER...........................................................................................................................204 Additional Features Of Premium Display Panel .......................................................................................204 Descriptions Of Additional Features (Available With The Premium Display) ...........................................................205 LCD SCREEN..........................................................................................................................205 OPERATOR PASSWORDS..................................................................................................................205 DAILY CHECK LIST AND SERVICE ITEMS..................................................................................................205 PERFORMANCE MODELS..................................................................................................................205 STATUS CODE LISTS...................................................................................................................205 ADJUSTMENTS OF BDI..................................................................................................................206 SEM DISPLAY PANEL INDICATORS............................................................................................................206 All Indicator Symbols...............................................................................................................206 Hourmeter Indicator Symbol..........................................................................................................207 Wrench Indicator Symbol.............................................................................................................207 Battery Indicator Symbol............................................................................................................207 Battery State-Of-Charge (BDI).......................................................................................................207 Brake Fluid Too Low Symbol..........................................................................................................207 Parking Brake Symbol................................................................................................................207 Fasten Seat Belt Symbol.............................................................................................................207 LCD "Screen" (Standard Display Panel)...............................................................................................207 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM.................................................................................207 Alpha Numeric "Screen"..............................................................................................................207 "Star" Push Button..................................................................................................................208 Push Buttons #1 Through #5..........................................................................................................208 OTHER CONTROL COMPONENTS................................................................................................................208 REPLACEMENT.................................................................................................................................209 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"................................................................................................209 Replace The Display Panel Assembly..................................................................................................209 Replace The Key Switch..............................................................................................................210 Indicator LEDs......................................................................................................................210 Battery Indicators..................................................................................................................210 Digital Display (Performance Display Panel Only) ...................................................................................210 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only)........................................212 Replace Parts Of The Basic Display Panel ...........................................................................................212 Replace Parts Of The Performance Display Panel......................................................................................213 SEM DISPLAY PANEL.......................................................................................................................214 Removal And Replacement.............................................................................................................214 REPLACE MOTOR CONTROLLER (SR or SP).....................................................................................................214 OTHER CONTROL COMPONENTS................................................................................................................214 Start Swtich........................................................................................................................214 Brake Light Switch..................................................................................................................215 Seat Switch.........................................................................................................................216 Adjust The External Seat Switch.....................................................................................................217 Switch For Optional Seat Brake......................................................................................................217 Parking Brake Switch................................................................................................................217 Direction Switches (Monotrol Pedal)................................................................................................218 Direction Control Switches (Steering Column)........................................................................................219 Direction Control Switches, E70-120XL3 (Steering Column)............................................................................220 Brake Fluid Switch..................................................................................................................220 Brush Wear And Over Temperature Sensors.............................................................................................220 Rocker Switches For Lights .........................................................................................................221 Accelerator Position Sensor.........................................................................................................221 On-Demand Steering Components.......................................................................................................223 Lights, Converter, Relay And Reverse Alarm..........................................................................................225 Horn And Horn Buttons...............................................................................................................228 Hydraulic Pump Switches.............................................................................................................229 CHECKS AND ADJUSTMENTS......................................................................................................................229 GENERAL.................................................................................................................................229 CONTROL AND POWER FUSES - "LX" OR "ZX"..................................................................................................229 CONTROL AND POWER FUSES - SEM...........................................................................................................232 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"............................................................................235 THERMAL SENSORS - SEM...................................................................................................................235 ADJUST THE START SWITCH.................................................................................................................235 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3...................................................................236 Direction Switches (MONOTROL).......................................................................................................238 ADJUST THE BRAKE LIGHT SWITCH.......................................................................................................238 CHECK SEAT SWITCH...................................................................................................................238 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE...........................................................................................238 ADJUST THE PARKING BRAKE SWITCH.....................................................................................................239 DIRECTIONAL SWITCHES................................................................................................................239 DIRECTIONAL SWITCHES (STEERING COLUMN)..............................................................................................239 HYDRAULIC PUMP SWITCHES.............................................................................................................239 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT......................................................................................239 ADJUST THE ACCELERATOR POSITION SENSOR..............................................................................................240 EV-100ZX Motor Controller Description & Repair..................................................................................................242 EV-100ZXE SCR MOTOR CONTROLLER, Description, Adjustments, Troubleshooting, Repairs, and Theory..............................................242 GENERAL.................................................................................................................................242 Model Number Data For EV-100ZX Controller...........................................................................................243 REGISTER PARAMETERS.....................................................................................................................252 General.............................................................................................................................252 Function Members....................................................................................................................252 CONTROL CARD, CHECKS AND ADJUSTMENTS....................................................................................................252 HAND SET................................................................................................................................253 How To Check And Adjust The Registers...............................................................................................253 How To Scroll Through The Fault Codes And Clear Them................................................................................253 Checks And Adjustments On The Work Bench............................................................................................254 When The Hand Set Is Connected To A Control Card Installed In A Lift Truck..........................................................255 FUNCTION NUMBER DESCRIPTIONS............................................................................................................256 TRACTION CONTROL CARDS (LABEL LETTERS - ZH AND ZY)......................................................................................257 PUMP CONTROL CARD (LABEL LETTER ZP).....................................................................................................263 REGISTER PARAMETERS.....................................................................................................................267 TROUBLESHOOTING.........................................................................................................................267 Status Codes........................................................................................................................268 REGISTER MAPS...........................................................................................................................268 STATUS CODE CHARTS..........................................................................................................................277 REPAIRS.....................................................................................................................................309 FUSES...................................................................................................................................310 CHECK AN SCR............................................................................................................................310 THE SCR ASSEMBLY........................................................................................................................311 THERMAL PROTECTOR.......................................................................................................................311 REPLACE THE SCR 1 ASSEMBLY..............................................................................................................311 THE "OFF" CIRCUIT FOR SCR 1.............................................................................................................311 Check The Reactor Assembly..........................................................................................................311 Check Suppressors For SCR 2 And SCR 5...............................................................................................312 Check SCR 2 And SCR 5...............................................................................................................312 Replace SCR 2 And SCR 5.............................................................................................................312 Check Capacitor C1..................................................................................................................312 DIODES D3 AND D4........................................................................................................................312 Check The Diodes D3 And D4..........................................................................................................313 Replacement, Diodes D3 And D4.......................................................................................................313 MOTOR CURRENT SENSOR....................................................................................................................313 CONTACTORS..............................................................................................................................313 Contactor Repair....................................................................................................................314 CONTROL CARD............................................................................................................................315 CONTROL CARD PLUGS......................................................................................................................316 Brush Wear Indicators...............................................................................................................317 THEORY OF OPERATION.........................................................................................................................318 ELECTRONIC SPEED CONTROLS...............................................................................................................318 The Silicon Controlled Rectifier (SCR)..............................................................................................318 A Motor Circuit That Operates With Pulses...........................................................................................318 Traction Circuit....................................................................................................................320 Hydraulic Pump Motor................................................................................................................320 The SCR 1 "OFF" Circuit.............................................................................................................321 INDUCTION CURRENT FROM THE MOTOR........................................................................................................323 CONTROL CARDS...........................................................................................................................323 Pulse Monitor Trip (PMT) (Traction Circuit Only)....................................................................................323 SRO Circuit (Traction Circuit Only).................................................................................................324 SEQUENCE OF OPERATION...................................................................................................................325 Control Card Adjustments (Traction Circuit).........................................................................................325 Accelerator Control.................................................................................................................328 SCR CONTROL (HYDRAULIC PUMP MOTOR)......................................................................................................328 CONTACTORS..............................................................................................................................329 CIRCUIT PROTECTION......................................................................................................................330 Traction Circuit Fuse...............................................................................................................330 Current Limit.......................................................................................................................330 Thermal Protection..................................................................................................................330 Suppressors.........................................................................................................................330 TRUCK MANAGEMENT MODULE (TMM1)..........................................................................................................330 TABLE 8. Terminal And Plug Wire Connections For TMM1 Module.........................................................................331 DISPLAY PANELS..........................................................................................................................331 Display Panel.......................................................................................................................331 Basic Display.......................................................................................................................331 Performance Display.................................................................................................................333 Brush Wear Indicators...............................................................................................................336 EV-100ZX Motor Controller Parameter Tables......................................................................................................337 EV-100ZX SCR MOTOR CONTROLLER, Parameter Tables.............................................................................................337 REGISTER PARAMETERS.....................................................................................................................337 General.............................................................................................................................337 Function Numbers....................................................................................................................338 CONTROL CARD, CHECKS AND ADJUSTMENTS....................................................................................................338 REGISTER PARAMETERS.....................................................................................................................338 TABLE 1. EV-100ZX Parameters - E/J2.00-3.20XM (E/J45-65XM) and N30XMH (36 to 48V)(Traction Card Type ZH With Regenerative Brakin....339 TABLE 2. EV-100ZX Parameters - E2.00-3.20XM (E45-65XM) and N30XMH (36 to 48V)(Traction Card Type ZY NO Regenerative Braking and ....342 TABLE 3. EV-100ZX Parameters - E/J2.00-3.20XM (72 to 80V)(Traction Card Type ZH with Regenerative Braking and Field Weakening.......345 TABLE 4. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V)(Traction Card Type ZY With Regenerative Braking And NO Field Weakening......348 TABLE 5. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V)(Low Energy Usage)(Traction Card Type ZY With 9-inch Motor, Regenerative.....351 TABLE 6. EV-100ZX Parameters - All Lift Trucks (36 to 48 volts)(Hydraulic Pump Card Type ZP)........................................354 TABLE 7. EV-100ZX Parameters - All Lift Trucks (72 to 80 volts)(Hydraulic Pump Card Type ZP)........................................357 EV-100ZX-T100 Troubleshooting & Adjustment With a Computer......................................................................................360 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers....................................360 COMPUTER SYSTEM.........................................................................................................................360 Connect A PC To A Control Card......................................................................................................361 HYTECt SOFTWARE PROGRAM ................................................................................................................362 How To Start The Program............................................................................................................362 Selecting The Communications Port...................................................................................................363 Verification Of Controller and Lift Truck...........................................................................................363 Select The Lift Truck Series........................................................................................................364 Undefined Controller Card...........................................................................................................365 Controller Card Register Parameter List.............................................................................................365 How To Enter A New Parameter........................................................................................................366 How To Save A Changed Parameter File................................................................................................367 How To Load A Saved Parameter File..................................................................................................367 How To Return To Factory Default Settings...........................................................................................368 How To Save Changes To The Controller Card..........................................................................................369 How To View The Status Codes .......................................................................................................369 Saving The Status Code To Disk......................................................................................................370 Closing and Clearing The Status Code List...........................................................................................371 COMMUNICATIONS PROGRAM (MODEM)..........................................................................................................371 Requirements........................................................................................................................372 README File.........................................................................................................................373 GE Sentry Software......................................................................................................................373 Getting Started.....................................................................................................................373 Where To Get Help...................................................................................................................374 Hardware and Software Requirements..................................................................................................374 Installation of the GE SENTRY SOFTWARE..............................................................................................374 How To Start The GE SENTRY Program..................................................................................................374 How To Reset The MIN and MAX Display................................................................................................376 How To Exit The GE SENTRY Program...................................................................................................376 Frame (E45-65XM)................................................................................................................................377 INTRODUCTION................................................................................................................................377 GENERAL.................................................................................................................................377 DESCRIPTION.............................................................................................................................377 Main Frame..........................................................................................................................377 Other Frame Weldments...............................................................................................................377 Battery Restraint/Hood Frame And Plate For Optional Seat Brake......................................................................379 Overhead Guard......................................................................................................................380 REPAIRS.....................................................................................................................................381 OVERHEAD GUARD..........................................................................................................................381 Removal.............................................................................................................................381 Installation........................................................................................................................381 BATTERY RESTRAINT AND SEAT ASSEMBLY.....................................................................................................381 COUNTERWEIGHT...........................................................................................................................382 Removal.............................................................................................................................382 Installation........................................................................................................................383 TRACTION MOTOR..........................................................................................................................383 Removal.............................................................................................................................383 Installation........................................................................................................................385 HYDRAULIC TANK..........................................................................................................................385 Inspection..........................................................................................................................385 Repairs, Small Leaks................................................................................................................385 Repairs, Large Leaks................................................................................................................386 Cleaning............................................................................................................................386 Steam Method Of Cleaning............................................................................................................386 Chemical Solution Method Of Cleaning................................................................................................386 Additional Preparations For Repair..................................................................................................387 PAINTING INSTRUCTIONS...................................................................................................................388 LABEL REPLACEMENT.......................................................................................................................389 Frame (J40-65XM)................................................................................................................................391 INTRODUCTION................................................................................................................................391 GENERAL ................................................................................................................................391 DESCRIPTION.............................................................................................................................391 Main Frame..........................................................................................................................391 Other Frame Weldments...............................................................................................................391 Battery Restraint/Hood Frame........................................................................................................391 Overhead Guard......................................................................................................................397 REPAIRS.....................................................................................................................................397 OVERHEAD GUARD..........................................................................................................................397 Removal.............................................................................................................................397 Installation........................................................................................................................397 BATTERY RESTRAINT AND SEAT ASSEMBLY.....................................................................................................397 Removal.............................................................................................................................397 COUNTERWEIGHT...........................................................................................................................398 Counterweight Removal...............................................................................................................398 Counterweight Installation..........................................................................................................399 TRACTION MOTOR..........................................................................................................................399 Motor Removal.......................................................................................................................399 Motor Installation..................................................................................................................400 HYDRAULIC TANK..........................................................................................................................401 Tank Removal........................................................................................................................401 Tank Inspection.....................................................................................................................401 Tank Repairs, Small Leaks...........................................................................................................401 Tank Repairs, Large Leaks...........................................................................................................401 Tank Cleaning.......................................................................................................................402 Steam Method Of Cleaning Tank.......................................................................................................402 Chemical Solution Method Of Cleaning Tank...........................................................................................402 Additional Preparations For Tank Repair.............................................................................................402 Tank Installation (See FIGURE 10.)..................................................................................................403 PAINTING INSTRUCTIONS...................................................................................................................404 LABEL REPLACEMENT.......................................................................................................................404 Global Mast Description.........................................................................................................................408 INTRODUCTION................................................................................................................................408 GENERAL.................................................................................................................................408 DESCRIPTION AND OPERATION...............................................................................................................408 Carriages...........................................................................................................................408 Mast Mounts.........................................................................................................................409 TWO-STAGE MAST, LIMITED FREE-LIFT.......................................................................................................410 Description and Operation...........................................................................................................410 TWO-STAGE MAST, FULL FREE-LIFT..........................................................................................................412 Description.........................................................................................................................412 Operation...........................................................................................................................412 THREE-STAGE, FULL FREE-LIFT MAST........................................................................................................414 Description.........................................................................................................................414 Operation...........................................................................................................................414 Global Mast Repair..............................................................................................................................416 INTRODUCTION ...............................................................................................................................416 GENERAL ................................................................................................................................416 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ...............................................................................................416 REPAIRS ....................................................................................................................................417 FORKS ..................................................................................................................................417 Removal ............................................................................................................................417 Installation .......................................................................................................................418 CARRIAGES ..............................................................................................................................418 Removal, Standard Carriage .........................................................................................................418 Removal, Side–Shift Carriage .......................................................................................................419 Repairs ............................................................................................................................419 Installation, Standard Carriage ....................................................................................................419 Installation, Side–Shift Carriage ..................................................................................................420 MAST ...................................................................................................................................421 Removal ............................................................................................................................421 Disassembly, Three–Stage FFL Mast ..................................................................................................427 Disassembly, Two–Stage LFL And Two–Stage FFL Masts .................................................................................421 Cleaning and Inspection ............................................................................................................427 Assembly, Two–Stage LFL And Two–Stage FFL Mast .....................................................................................430 Assembly, Three–Stage FFL Mast .....................................................................................................431 Installation, Mast .................................................................................................................432 LIFT CYLINDERS .........................................................................................................................433 Removal, Main Lift Cylinders .......................................................................................................433 Removal, Free–Lift Cylinder ........................................................................................................433 Disassembly, Lift Cylinders ........................................................................................................433 Assembly, Lift Cylinders ...........................................................................................................434 Installation, Main Lift Cylinders ..................................................................................................435 Installation, Free–Lift Cylinder ...................................................................................................436 HEADER HOSE ARRANGEMENTS H/S/E/J2.00–3.20XM (H/S/E/J40–65XM) S/E/J2.00–3.00XL (S/E/J40–60XL) ...........................................437 New Hose Installation, Two–Stage, LFL Mast .........................................................................................437 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .........................................................................437 New Hose Installation, Two–Stage FFL Mast ..........................................................................................441 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .........................................................................441 New Hose Installation, Three–Stage FFL Mast ........................................................................................445 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ......................................................................450 HEADER HOSE ARRANGEMENTS H/E1.50–1.75XM, H/S2.00XMS (H/S/E25–35XM, H/S/E40XMS) and J1.60–2.00XMT (J30–40XMT) ...........................452 New Hose Installation, Two–Stage LFL Mast ..........................................................................................453 Adjustment Of Hoses After Installation, Two–Stage LFL Mast .........................................................................453 New Hose Installation, Two–Stage FFL Mast ..........................................................................................456 Adjustment Of Hoses After Installation, Two–Stage FFL Mast .........................................................................456 New Hose Installation, Three–Stage, FFL Mast .......................................................................................460 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ......................................................................465 CHECKS AND ADJUSTMENTS .....................................................................................................................466 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ...........................................................................................466 Check The Lift Cylinders For Leaks ................................................................................................466 Check The Tilt Cylinders For Leaks ................................................................................................466 ADJUST THE TILT CYLINDERS .............................................................................................................466 ADJUST THE LIFT CHAINS ................................................................................................................467 ADJUST THE MAST .......................................................................................................................468 ADJUST THE CARRIAGE ...................................................................................................................469 TROUBLESHOOTING.............................................................................................................................470 Hydraulic System................................................................................................................................471 INTRODUCTION................................................................................................................................471 GENERAL.................................................................................................................................471 DESCRIPTION.............................................................................................................................472 Hydraulic System....................................................................................................................472 OPERATION...............................................................................................................................472 Hydraulic System....................................................................................................................472 Hydraulic Gear Pump.................................................................................................................473 Rotator Actuator Valve..............................................................................................................473 Steering Pump.......................................................................................................................476 REPAIRS.....................................................................................................................................480 HYDRAULIC TANK..........................................................................................................................480 E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal.....................................................................................480 J2.00-3.20XM (J40-65XM) Tank Removal................................................................................................480 Tank Inspection.....................................................................................................................480 Tank Repairs, Small Leaks...........................................................................................................481 Tank Repairs, Large Leaks ..........................................................................................................481 Tank Cleaning.......................................................................................................................481 Steam Method Of Cleaning Tank.......................................................................................................481 Chemical Solution Method Of Cleaning Tank...........................................................................................481 Additional Preparations For Tank repair.............................................................................................482 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation................................................................................482 J2.00-3.20XM (J40-65XM) Tank Installation...........................................................................................482 FILTER REPLACEMENT......................................................................................................................483 HYDRAULIC PUMP..........................................................................................................................483 Removing E1.50-3.20XM (E25-65XM) and N30XMH Hydraulic Pump..........................................................................483 Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump...................................................................................484 Pump Seal Replacement And Pump Assembly.............................................................................................484 Assemble Pump On The Motor..........................................................................................................486 Install The Hydraulic Pump And Motor Assembly [E1.50-3.20XM (E25-65XM) and N30XMH]..................................................487 Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly...................................................................487 MAIN CONTROL VALVE......................................................................................................................488 STEERING PUMP...........................................................................................................................488 Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N30XMH....................................................................488 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM)...............................................................................489 Pump Assembly And Installation......................................................................................................490 ROTARY ACTUATOR VALVE...................................................................................................................491 Disassembly, Cleaning and Inspection................................................................................................491 Assembly............................................................................................................................491 STEERING CONTROL UNIT...................................................................................................................491 Control Unit Removal................................................................................................................492 Control Unit Installation...........................................................................................................492 STEERING CYLINDER.......................................................................................................................492 CHECKS AND ADJUSTMENTS......................................................................................................................494 MAIN CONTROL VALVE......................................................................................................................494 STEERING RELIEF VALVE...................................................................................................................494 TROUBLESHOOTING CHART.......................................................................................................................494 SPECIFICATIONS..............................................................................................................................498 Industrial Battery..............................................................................................................................501 INTRODUCTION................................................................................................................................501 GENERAL.................................................................................................................................501 LEAD-ACID BATTERIES.....................................................................................................................501 SPECIFIC GRAVITY........................................................................................................................502 CHEMICAL REACTION IN A CELL.............................................................................................................502 ELECTRICAL TERMS........................................................................................................................503 HOW TO SELECT THE BATTERY...............................................................................................................503 VOLTAGE OF A BATTERY....................................................................................................................503 THE BATTERY AS A COUNTERWEIGHT..........................................................................................................504 BATTERY RATINGS.........................................................................................................................504 Kilowatt-Hours......................................................................................................................505 BATTERY MAINTENANCE.........................................................................................................................505 SAFETY PROCEDURES.......................................................................................................................505 MAINTENCE RECORDS.......................................................................................................................506 THE NEW BATTERY.........................................................................................................................506 HOW TO CLEAN THE BATTERY................................................................................................................507 HOW TO ADD WATER........................................................................................................................507 THE HYDROMETER..........................................................................................................................508 BATTERY TEMPERATURE.....................................................................................................................508 CHARGING THE BATTERY....................................................................................................................509 Types Of Battery Charges............................................................................................................510 Methods Of Charging.................................................................................................................511 Troubleshooting The Charger.........................................................................................................511 How to Know When The Battery Is Fully Charged.......................................................................................512 WHERE TO CHARGE THE BATTERIES...........................................................................................................512 Equipment Needed....................................................................................................................512 BATTERY CONNECTORS......................................................................................................................513 BATTERY CARE............................................................................................................................513 Instrument Clusters.............................................................................................................................515 INTRODUCTION................................................................................................................................515 GENERAL.................................................................................................................................515 DESCRIPTION.............................................................................................................................515 REPAIRS.....................................................................................................................................519 REMOVAL AND DISASSEMBLY.................................................................................................................519 ASSEMBLY AND INSTALLATION...............................................................................................................519 Main Control Valve..............................................................................................................................522 INTRODUCTION................................................................................................................................522 GENERAL.................................................................................................................................522 DESCRIPTION.............................................................................................................................522 OPERATION...............................................................................................................................523 E1.50-3.20XM (E25-65XM).............................................................................................................524 J2.00-3.20XM (J40-65XM).............................................................................................................524 Lift Section........................................................................................................................524 Tilt Section........................................................................................................................525 Relief Valve........................................................................................................................527 REPAIRS.....................................................................................................................................528 MAIN CONTROL VALVE......................................................................................................................528 Removal.............................................................................................................................528 Disassembly.........................................................................................................................528 Cleaning And Inspection.............................................................................................................528 Assembly............................................................................................................................528 Installation, E1.50-3.20XM (E25-65XM)...............................................................................................530 Installation, J2.00-3.20XM (J40-65XM)...............................................................................................532 CONTROL LEVER LINKAGE, E1.50-3.20XM (E25-65XM)..........................................................................................533 Removal.............................................................................................................................533 Disassembly.........................................................................................................................534 Assembly And Installation...........................................................................................................534 CONTROL VALVE LINKAGE, E1.50-3.20XM (E25-65XM)..........................................................................................534 Removal And Disassembly.............................................................................................................534 Assembly And Installation...........................................................................................................535 CONTROL LEVER LINKAGE, J2.00-3.20XM (J40-65XM)..........................................................................................535 Removal.............................................................................................................................535 Disassembly.........................................................................................................................535 Assembly And Installation...........................................................................................................537 CHECKS AND ADJUSTMENTS......................................................................................................................538 PRESSURE RELIEF VALVES..................................................................................................................538 Primary Relief Valve................................................................................................................538 Secondary Relief Valve..............................................................................................................538 TROUBLESHOOTING.............................................................................................................................539 Periodic Maintenance............................................................................................................................541 INTRODUCTION................................................................................................................................541 GENERAL.................................................................................................................................541 SERIAL NUMBER DATA......................................................................................................................541 HOW TO MOVE A DISABLED LIFT TRUCK.......................................................................................................541 How To Tow A Lift Truck ............................................................................................................541 HOW TO PUT A LIFT TRUCK ON BLOCKS.......................................................................................................542 How To Raise The Drive Tires........................................................................................................542 How To Raise The Steering Tires.....................................................................................................542 MAINTENANCE SCHEDULE........................................................................................................................543 MAINTENANCE PROCEDURES......................................................................................................................546 EVERY 8 HOURS OR DAILY......................................................................................................................546 Tires And Wheels........................................................................................................................546 Forks...................................................................................................................................547 Fork Adjustment.........................................................................................................................547 Fork Removal............................................................................................................................547 Fork Installation.......................................................................................................................548 Inspection Of Forks, Mast And Lift Chains...............................................................................................548 Safety Labels...........................................................................................................................549 Steering Column Latch...................................................................................................................549 Operator Restraint System...............................................................................................................550 Battery Restraint System, E25-65XM, E25-65XM2..........................................................................................550 Battery Restraint System - J40-65XM-65XM, J40-65XM2....................................................................................551 Battery.................................................................................................................................551 Hydraulic System........................................................................................................................552 HOW TO MAKE CHECKS WITH THE KEY "ON"....................................................................................................553 Gauges, Horn And Fuses..............................................................................................................553 Steering System.....................................................................................................................553 Service Brake.......................................................................................................................553 Parking Brake.......................................................................................................................554 Control Levers And Pedals...........................................................................................................554 Lift System Operation...............................................................................................................554 EVERY 350 HOURS OR THREE MONTHS ............................................................................................................555 HYDRAULIC TANK BREATHER.................................................................................................................555 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................555 WHEEL NUT TORQUES.......................................................................................................................556 STEERING AXLE SPINDLES..................................................................................................................556 MAST....................................................................................................................................556 LIFT CHAINS.............................................................................................................................557 Check For Wear......................................................................................................................557 Lubrication.........................................................................................................................557 FORKS...................................................................................................................................557 BRAKE FLUID.............................................................................................................................558 OTHER LUBRICATION.......................................................................................................................558 SEAT BRAKE (E25-65XM, E25-65XM2 Only....................................................................................................558 ELECTRICAL INSPECTION...................................................................................................................558 Contactors..........................................................................................................................559 Motor Brushes.......................................................................................................................559 Motor Brushes, General..............................................................................................................559 EVERY 2000 HOURS OR YEARLY..................................................................................................................569 HYDRAULIC SYSTEM........................................................................................................................569 Change The Filter For The Hydraulic Oil.............................................................................................569 Change The Hydraulic Oil............................................................................................................570 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................570 SERVICE BRAKES..........................................................................................................................570 CONTACTORS..............................................................................................................................571 WHEEL BEARINGS..........................................................................................................................571 Steer Wheels, Lubrication...........................................................................................................571 Drive Wheels, Lubrication...........................................................................................................571 LIFT CHAINS.............................................................................................................................571 GENERAL PROCEDURE...........................................................................................................................571 HOW TO CHARGE THE BATTERY...............................................................................................................571 HOW TO CHANGE THE BATTERY...............................................................................................................573 General.............................................................................................................................573 Change The E25-65XM, E25-65XM2 Battery..............................................................................................573 Change The J40-65XM, J40-65XM2 Battery..............................................................................................575 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................................577 Check The Lift Cylinders For Leaks..................................................................................................577 Check The Tilt Cylinders For Leaks..................................................................................................577 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)...................................................................................578 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)...................................................................................579 LIFT CHAIN ADJUSTMENTS..................................................................................................................579 HOW TO CHECK THE PMT CIRCUIT............................................................................................................580 WELDING REPAIRS.........................................................................................................................581 CHANGES TO THE OVERHEAD GUARD...........................................................................................................581 TIRES AND WHEELS, E25-65XM, E25-65XM2...................................................................................................581 Remove The Wheels From The Lift Truck..............................................................................................582 Remove And Install The Tire On The Wheel............................................................................................582 PNEUMATIC TIRES AND WHEELS J40-65XM, J40-65XM2..........................................................................................582 Remove The Wheels From The Lift Truck...............................................................................................582 Remove The Wheel From The Pneumatic Tire............................................................................................583 Install The Wheel In The Pneumatic Tire.............................................................................................584 Add Air To The Tires................................................................................................................585 Install The Wheels..................................................................................................................585 SOLID RUBBER TIRES ON PNEUMATIC WHEELS..................................................................................................585 Remove The Wheels From The Lift Truck...............................................................................................585 Remove The Solid Rubber Tire From The Pneumatic Wheel...............................................................................585 Install The Solid Rubber Tire On The Pneumatic Wheel................................................................................587 Install The Wheels .................................................................................................................587 REFERENCE TABLE.............................................................................................................................588 Adhesive And Sealants ..................................................................................................................588 SAE & Metric Fasteners..........................................................................................................................589 INTRODUCTION................................................................................................................................589 NOMENCLATURE, THREADS...................................................................................................................589 STRENGTH IDENTIFICATION.................................................................................................................590 TABLE 1. BOLTS AND SCREWS...................................................................................................................590 TABLE 2. STUDS AND NUTS.....................................................................................................................591 TABLE 3. TORQUE NUTS........................................................................................................................592 TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................................593 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................................594 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................................595 Steering Axle (E45-65XM)........................................................................................................................598 INTRODUCTION................................................................................................................................598 GENERAL.................................................................................................................................598 DESCRIPTION.............................................................................................................................598 REPAIRS.....................................................................................................................................599 STEERING AXLE ASSEMBLY..................................................................................................................599 Removal.............................................................................................................................599 Installation........................................................................................................................599 WHEELS..................................................................................................................................599 Removal And Disassembly.............................................................................................................599 Cleaning............................................................................................................................599 Assembly And Installation...........................................................................................................600 SPINDLES, BEARINGS, AND TIE RODS........................................................................................................600 Removal And Disassembly.............................................................................................................600 Assembly And Installation...........................................................................................................601 STEERING CYLINDER.......................................................................................................................602 Removal And Disassembly.............................................................................................................602 Cleaning And Inspection.............................................................................................................602 Assembly And Installation...........................................................................................................602 TROUBLESHOOTING.............................................................................................................................603 TORQUE SPECIFICATIONS.......................................................................................................................603 Steering Axle (J40-65XM)........................................................................................................................605 STEERING SYSTEM.............................................................................................................................605 GENERAL.................................................................................................................................605 DESCRIPTION.............................................................................................................................607 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................608 Removal Of The Assembly Components..................................................................................................608 Installation Of The Assembly Components.............................................................................................612 POWER STEERING MOTOR AND PUMP...............................................................................................................613 DESCRIPTION.............................................................................................................................613 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)......................................613 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)...........................................................................613 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)........................................................................................614 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL).......................................................................................616 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)......................................................................................617 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]..........................................617 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)......................................................................................618 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)....................................................................................620 REPAIRS, POWER STEERING PUMP............................................................................................................621 Seal Replacement....................................................................................................................622 HYDRAULIC STEERING MOTOR....................................................................................................................622 DESCRIPTION.............................................................................................................................622 REPAIRS, HYDRAULIC STEERING MOTOR.......................................................................................................623 Removal ............................................................................................................................623 Disassembly.........................................................................................................................623 Cleaning And Inspection.............................................................................................................623 Assembly............................................................................................................................624 Installation, Hydraulic Steering Motor..............................................................................................625 CHECKS AND ADJUSTMENTS......................................................................................................................625 AIR IN THE STEERING SYSTEM..............................................................................................................625 CHECK STEERING PRESSURE.................................................................................................................625 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)...........................................................................626 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS...........................................................................................627 TROUBLESHOOTING.............................................................................................................................629 Steering Housing & Control Unit.................................................................................................................632 INTRODUCTION................................................................................................................................632 GENERAL.................................................................................................................................632 DESCRIPTION.............................................................................................................................632 OPERATION...............................................................................................................................632 REPAIRS.....................................................................................................................................633 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................633 Removal of the Assembly Components..................................................................................................637 Disassembly of the Steering Control Unit............................................................................................638 Cleaning of the Steering Control Unit...............................................................................................638 Assembly of the Steering Control Unit...............................................................................................638 Installation of the Steering Control Unit...........................................................................................638 Installation of the Assembly Components.............................................................................................638 CHECKS AND ADJUSTMENTS......................................................................................................................646 REMOVE AIR FROM THE SYSTEM..............................................................................................................646 TROUBLESHOOTING.............................................................................................................................646 Steering System.................................................................................................................................648 STEERING SYSTEM.............................................................................................................................648 GENERAL.................................................................................................................................648 DESCRIPTION.............................................................................................................................650 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................651 Removal Of The Assembly Components..................................................................................................651 Installation Of The Assembly Components.............................................................................................655 POWER STEERING MOTOR AND PUMP...............................................................................................................656 DESCRIPTION.............................................................................................................................656 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)......................................656 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)...........................................................................656 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)........................................................................................657 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL).......................................................................................659 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)......................................................................................660 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]..........................................660 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)......................................................................................661 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)....................................................................................663 REPAIRS, POWER STEERING PUMP............................................................................................................664 Seal Replacement....................................................................................................................665 HYDRAULIC STEERING MOTOR....................................................................................................................665 DESCRIPTION.............................................................................................................................665 REPAIRS, HYDRAULIC STEERING MOTOR.......................................................................................................666 Removal ............................................................................................................................666 Disassembly.........................................................................................................................666 Cleaning And Inspection.............................................................................................................666 Assembly............................................................................................................................667 Installation, Hydraulic Steering Motor..............................................................................................668 CHECKS AND ADJUSTMENTS......................................................................................................................668 AIR IN THE STEERING SYSTEM..............................................................................................................668 CHECK STEERING PRESSURE.................................................................................................................668 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)...........................................................................669 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS...........................................................................................670 TROUBLESHOOTING.............................................................................................................................672 Tilt Cylinders..................................................................................................................................675 INTRODUCTION................................................................................................................................675 GENERAL.................................................................................................................................675 DESCRIPTION.............................................................................................................................675 REPAIRS.....................................................................................................................................675 REMOVAL.................................................................................................................................675 DISASSEMBLY.............................................................................................................................675 CLEANING................................................................................................................................675 ASSEMBLY................................................................................................................................675 Tilt Cylinders with O-Rings or Single Lip Seals.....................................................................................675 Tilt Cylinders for the XM and XMS Models............................................................................................676 Tilt Cylinders for H700 800A and Early Model H700 920B..............................................................................678 INSTALLATION............................................................................................................................678 Tilt Cylinders Using Chevron Packing................................................................................................679 CHECKS AND ADJUSTMENTS......................................................................................................................681 CHECK THE TILT CYLINDERS FOR LEAKS......................................................................................................681 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.................................................................................681 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS....................................................................................682 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS...................................................................................683 TROUBLESHOOTING.............................................................................................................................685
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