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Hyster Forklift J1 60XMT, J1 80XMT, J2 00XMTE160 service manual – PDF DOWNLOAD
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Hyster Forklift J1 60XMT, J1 80XMT, J2 00XMTE160 service manual
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Hyster Forklift J1 60XMT, J1 80XMT, J2 00XMTE160 service manual
Language : English
Pages : 520
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HYSTER FORKLIFT J1 60XMT, J1 80XMT, J2 00XMTE160 SERVICE MANUAL – PDF DOWNLOAD:
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Hyster Forklift J1 60XMT, J1 80XMT, J2 00XMTE160 service manual
- The lift truck can have one of two types of battery indicators. One type of indicator does NOT have Lift Interrupt and is not adjustable. The other type of battery indicator HAS Lift Interrupt and is adjustable for different batteries or operating conditions.
- The indicator that does not have Lift Interrupt is a voltmeter. The face of the meter has a green and red band. Some meters also have a yellow band between the red and green bands. During operation, the indicator needle moves from the green to the red band to indicate a discharged battery. When the battery is fully charged, the needle is in the green band. The early (D of FIGURE 1.) battery indicator with Lift Interrupt automatically measures the charge of the battery.
- A separate controller for the meter has an electronic circuit. This circuit controls the meter movement, a warning light (early units only) and an electronic switch for the main hydraulic pump. The circuit can remember the charge on the battery when the battery is disconnected and connected.
- The meter face has a band that is red at the left end and green at the right. Some indicators have a split area with green on top and yellow on the bottom. Some other meters have a yellow band between the red and green bands. The needle location indicates the battery charge level.
- When the needle is at the edge of the red area of the band, the warning light illuminates if the indicator has one. At this point, the battery has approximately 5% (reserve) capacity remaining. If the reserve is used, the needle enters the red band and power to the hydraulic pump motor is interrupted until the battery is charged or replaced. Normally there is enough battery power to move the lift truck to a battery charger or to a place where a charged battery can be installed. When the needle of the indicator is in the red band, the battery
Table of Contents:
Hyster Forklift J1 60XMT, J1 80XMT, J2 00XMTE160 service manual
INTRODUCTION........................................................................................ 1 GENERAL......................................................................................... 1 INDICATORS WITH METER MOVEMENTS................................................................. 2 BATTERY INDICATORS WITH LCD OR LED DISPLAYS..................................................... 3 Liquid Crystal Displays..................................................................... 3 Light Emitting Diode Displays............................................................... 4 CHECKS AND ADJUSTMENTS.............................................................................. 7 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARYLY MODELS........................................ 7 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS............................................ 8 Reset Potentiometer......................................................................... 8 Specific Gravity Alarm...................................................................... 8 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS......................................... 8 BATTERY INDICATORS WITH LIFT INTERRUPT, LATER MODELS............................................ 8 Reset Potentiometer......................................................................... 9 Discharge Potentiometer..................................................................... 9 LED DISPLAY WITH LIFT INTERRUPT................................................................. 9 CHECKING CURTIS 933-1 METER..................................................................... 9 Reset Check ................................................................................ 10 Discharge Check............................................................................. 10 Lockout Check............................................................................... 11 Hour Glass Icon............................................................................. 11 ADJUSTMENT OF CURTIS 933-1 METER................................................................ 12 CHECKING CURTIS 1215 BATTERY INDICATOR.......................................................... 12 ADJUSTING CURTIS 1215 BATTERY INDICATOR......................................................... 13 Voltage Selection........................................................................... 14 REPAIRS............................................................................................. 15 BATTERY INDICATORS.................................................................................. 15 Replacement..................................................................................... 15 CONTROLLER FOR THE BATTERY INDICATOR................................................................ 15 Replacement..................................................................................... 15 DISPLAY PANEL COMPONENTS............................................................................ 15 INTRODUCTION........................................................................................ 18 GENERAL......................................................................................... 18 DESCRIPTION..................................................................................... 18 REPAIRS............................................................................................. 18 SERVICE BRAKE PADS.............................................................................. 18 Removal..................................................................................... 18 Installation................................................................................ 18 SERVICE BRAKE CALIPER........................................................................... 19 Removal..................................................................................... 19 Installation................................................................................ 19 Disassembly................................................................................. 20 Assembly.................................................................................... 21 PARK BRAKE CALIPER.............................................................................. 21 Removal..................................................................................... 21 Installation................................................................................ 21 Disassembly................................................................................. 21 Assembly.................................................................................... 22 MASTER CYLINDER................................................................................. 22 Removal..................................................................................... 22 Installation................................................................................ 23 Disassembly................................................................................. 23 Assembly.................................................................................... 23 FOOT OPERATED PARK BRAKE LEVER.................................................................. 24 Removal..................................................................................... 24 Installation................................................................................ 24 ELECTRICALLY RELEASED PARK BRAKE................................................................ 26 Mechanical Operation........................................................................ 26 Removal..................................................................................... 26 Installation................................................................................ 28 ELECTRICALLY RELEASED PARK BRAKE-ELECTRICAL COMPONENTS.......................................... 29 Control Box-Removal......................................................................... 29 Control Box-Installation.................................................................... 31 Terminal Block-Removal...................................................................... 31 Terminal Block-Installation................................................................. 31 CHECKS AND ADJUSTMENTS.............................................................................. 31 PARK BRAKE ADJUSTMENT........................................................................... 31 SERVICE BRAKE ADJUSTMENT........................................................................ 32 REMOVE AIR FROM THE BRAKE SYSTEM................................................................ 32 TROUBLESHOOTING..................................................................................... 33 INTRODUCTION........................................................................................ 35 ELECTRIC MOTOR MAINTENANCE, GENERAL............................................................. 35 BRUSH AND COMMUTATOR INSPECTION................................................................. 35 Hydraulic Pump Motor And Traction Motor..................................................... 35 Steering Pump Motor......................................................................... 37 TROUBLESHOOTING..................................................................................... 37 TROUBLESHOOTING................................................................................. 37 Commutator Problems......................................................................... 40 BRUSH REPLACEMENT............................................................................... 42 DISASSEMBLY OF MOTORS........................................................................... 44 Traction Motor And Hydraulic Pump Motor..................................................... 44 Steering Pump Motor......................................................................... 47 ASSEMBLY OF MOTORS.............................................................................. 49 Traction Motor And Hydraulic Pump Motor..................................................... 49 Steering Pump Motor......................................................................... 49 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS.................................................. 49 TESTS FOR A DAMAGED FIELD AND ARMATURE.......................................................... 49 Test For An Open Circuit In The Armature.................................................... 50 Test For A Short–Circuit In One Armature Winding............................................ 50 Test For A Short–Circuit To Armature Shaft.................................................. 50 Test For An Open Circuit In A Field Coil.................................................... 51 Test For A Short–Circuit In A Field Coil.................................................... 51 Test For A Short–Circuit Between The Field And The Motor Case............................... 51 Brush Holder Test........................................................................... 51 INTRODUCTION........................................................................................ 52 GENERAL......................................................................................... 52 DESCRIPTION......................................................................................... 52 INSTRUMENT PANEL................................................................................ 52 Standard Display............................................................................ 53 Premium Display............................................................................. 53 PRINTED CIRCUIT BOARDS.......................................................................... 55 Steering Angle Control Board................................................................ 55 Lift Pump Control Board..................................................................... 56 OTHER CONTROL COMPONENTS........................................................................ 56 REPLACEMENT......................................................................................... 57 INSTRUMENT PANEL COMPONENTS..................................................................... 57 Instrument Panel Assembly................................................................... 57 Key Switch.................................................................................. 59 Battery Indicators.......................................................................... 59 Hourmeter (Standard Panel Only)............................................................. 59 Digital Display (Premium Panel Only)........................................................ 59 Indicator Lights............................................................................ 59 PRINTED CIRCUIT BOARDS.......................................................................... 59 Steering Angle Control Board................................................................ 59 Lift Pump Control Board..................................................................... 60 OTHER CONTROL COMPONENTS........................................................................ 60 Accelerator Switch Assembly................................................................. 60 Seat Switch................................................................................. 61 Parking Brake Switch........................................................................ 61 Direction Switches (Monotrol Pedal)......................................................... 61 Direction Control Switches (Steering Column)................................................ 61 Hydraulic Cut Off Switch.................................................................... 64 Brake Fluid Switch.......................................................................... 64 Motor Temperature Switches.................................................................. 64 Stop Light Switch........................................................................... 64 Rocker Switches for Lights.................................................................. 65 Lights and Reverse Alarm.................................................................... 65 DC to DC Converter.......................................................................... 66 Light Relay Panel........................................................................... 72 Light Switch Relay.......................................................................... 72 Back-up Alarm Relay......................................................................... 72 Horn and Horn Button........................................................................ 72 CHECKS AND ADJUSTMENTS.............................................................................. 74 CONTROL POWER FUSES............................................................................. 74 CHECK ACCELERATOR SWITCH ASSEMBLY............................................................... 75 ADJUSTING STOP LIGHT SWITCH..................................................................... 75 CHECK SEAT SWITCH............................................................................... 75 ADJUSTING PARKING BRAKE SWITCH.................................................................. 76 DIRECTION SWITCHES (MONOTROL PEDAL)............................................................. 76 DIRECTION SWITCHES (STEERING COLUMN)............................................................ 76 HYDRAULIC CUT OFF SWITCH........................................................................ 76 PRINTED CIRCUIT BOARDS.......................................................................... 80 Steering Angle Control Board................................................................ 80 Lift Pump Control Board..................................................................... 84 Bypassing the Lift Pump Control Board....................................................... 85 INTRODUCTION........................................................................................ 88 NOMENCLATURE, THREADS........................................................................... 88 STRENGTH IDENTIFICATION......................................................................... 89 TABLE 1. BOLTS AND SCREWS........................................................................... 89 TABLE 2. STUDS AND NUTS............................................................................. 90 TABLE 3. TORQUE NUTS................................................................................ 91 TABLE 4. TORQUE NUTS WITH NYLON INSERT.............................................................. 92 TABLE 5. TORQUE VALUES FOR INCH FASTENERS........................................................... 93 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS......................................................... 94 INTRODUCTION........................................................................................ 98 GENERAL......................................................................................... 98 DESCRIPTION..................................................................................... 98 REPAIRS............................................................................................. 99 OVERHEAD GUARD.................................................................................. 99 Removal..................................................................................... 99 Installation................................................................................ 99 HOOD AND SEAT ASSEMBLY..........................................................................100 Removal.....................................................................................101 Installation................................................................................101 COUNTERWEIGHT...................................................................................102 Removal.....................................................................................102 Installation................................................................................103 AUXILIARY COUNTERWEIGHT.........................................................................103 Removal.....................................................................................103 Installation................................................................................104 HYDRAULIC TANK..................................................................................104 Inspection..................................................................................104 Repairs, Small Leaks........................................................................104 Repairs, Large Leaks........................................................................104 Cleaning....................................................................................104 Steam Method Of Cleaning....................................................................104 Chemical Solution Method Of Cleaning........................................................105 Additional Preparations For Repair..........................................................105 SAFETY LABELS...................................................................................105 INTRODUCTION........................................................................................111 GENERAL.........................................................................................111 DESCRIPTION.....................................................................................111 REPAIRS.............................................................................................115 REMOVAL AND DISASSEMBLY.........................................................................115 ASSEMBLY AND INSTALLATION.......................................................................115 INTRODUCTION........................................................................................118 GENERAL.........................................................................................118 LEAD-ACID BATTERIES.............................................................................118 SPECIFIC GRAVITY................................................................................118 THE CHEMICAL REACTION IN A CELL.................................................................119 ELECTRICAL TERMS....................................................................................120 HOW TO SELECT THE BATTERY.......................................................................120 VOLTAGE OF A BATTERY............................................................................120 THE BATTERY AS A COUNTERWEIGHT..................................................................121 BATTERY RATINGS.................................................................................121 Kilowatt-Hours..............................................................................122 BATTERY MAINTENANCE.................................................................................122 SAFETY PROCEDURES...............................................................................122 MAINTENACE RECORDS..............................................................................123 THE NEW BATTERY.................................................................................123 HOW TO CLEAN THE BATTERY........................................................................124 HOW TO ADD WATER................................................................................124 THE HYDROMETER..................................................................................125 BATTERY TEMPERATURE.............................................................................125 CHARGING THE BATTERY............................................................................126 Types Of Battery Charges....................................................................127 Methods Of Charging.........................................................................128 Troubleshooting The Charger.................................................................128 How To Know When The Battery Is Fully Charged...............................................129 WHERE TO CHARGE THE BATTERIES...................................................................129 Equipment Needed............................................................................129 BATTERY CONNECTORS..............................................................................130 BATTERY CARE....................................................................................130 INTRODUCTION........................................................................................134 GENERAL.........................................................................................134 DESCRIPTION.....................................................................................134 OPERATION.......................................................................................135 Lift Section................................................................................135 Tilt Section................................................................................136 Relief Valve................................................................................136 REPAIRS.............................................................................................136 MAIN CONTROL VALVE..............................................................................136 Removal.....................................................................................136 Installation................................................................................137 Disassembly.................................................................................140 Cleaning And Inspection.....................................................................142 Assembly....................................................................................142 CHECKS AND ADJUSTMENTS..............................................................................143 RELIEF VALVE....................................................................................143 VANE SETTINGS...................................................................................143 MAST TILT ADJUSTMENT............................................................................143 TROUBLESHOOTING.....................................................................................144 INTRODUCTION........................................................................................147 GENERAL.........................................................................................147 HOW TO MOVE A DISABLED LIFT TRUCK...............................................................147 How to Tow a Lift Truck.....................................................................147 HOW TO PUT A LIFT TRUCK ON BLOCKS...............................................................148 How to Raise the Load Wheels................................................................148 How to Raise the Steer Wheel................................................................149 MAINTENANCE SCHEDULE................................................................................149 MAINTENANCE POINTS..............................................................................149 MAINTENANCE SCHEDULE............................................................................150 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY.......................................................151 CHECKS BEFORE OPERATION.........................................................................151 Hydraulic System............................................................................151 Battery.....................................................................................152 Battery Restraint System....................................................................152 Tyres and Wheels............................................................................153 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................154 Forks.......................................................................................155 Forks, Adjustment...........................................................................155 Forks, Removal..............................................................................156 Forks, Inspection...........................................................................156 Forks, Installation.........................................................................157 Mast and Lift Chains........................................................................157 Lift Chain Adjustment.......................................................................158 CHECK THE OPERATION.............................................................................158 Gauges and Horn.............................................................................158 Control Levers and Pedals...................................................................159 Service Brakes..............................................................................159 Parking Brake...............................................................................159 Steering System.............................................................................159 EVERY 500 HOURS OR THREE MONTHS.....................................................................159 HYDRAULIC TANK BREATHER.........................................................................159 WHEEL NUT TORQUE................................................................................159 TRANSAXLE.......................................................................................159 LIFT SYSTEM OPERATION...........................................................................160 MAST............................................................................................160 LIFT CHAINS.....................................................................................161 FORKS...........................................................................................162 SAFETY LABELS...................................................................................162 BRAKE FLUID.....................................................................................162 OTHER LUBRICATION...............................................................................162 ELECTRICAL INSPECTION...........................................................................162 Contactors..................................................................................162 Motor Brushes...............................................................................165 Parking Brake...............................................................................165 2000 HOURS OR YEARLY................................................................................165 HYDRAULIC SYSTEM................................................................................165 Change the Hydraulic Oil Filter.............................................................165 Check the Hydraulic Oil Strainer............................................................166 Change the Hydraulic Oil....................................................................166 BRAKES..........................................................................................166 Adjust the Parking Brake....................................................................167 TRANSAXLE.......................................................................................167 EVERY 4000 HOURS....................................................................................168 TRANSAXLE (S2 SERIES ONLY).....................................................................168 GENERAL PROCEDURES..................................................................................168 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................168 Lift System.................................................................................168 Tilt System.................................................................................168 HOW TO CHECK THE PMT CIRCUIT....................................................................169 HOW TO CHARGE THE BATTERY.......................................................................169 HOW TO CHANGE THE BATTERY.......................................................................170 WHEELS AND TYRES....................................................................................171 GENERAL.........................................................................................171 HOW TO CHANGE THE TYRES.........................................................................171 STEER AND DRIVE WHEELS..........................................................................172 PNEUMATIC TYRES.................................................................................172 Remove the Wheel from the Lift Truck........................................................172 Tyre Sizes and Pressures....................................................................172 Remove the Tyre from the Wheel..............................................................173 Install the Tyre on the Wheel...............................................................173 PNEUMATIC SHAPED SOLID TYRES....................................................................174 Remove the Wheel from the Lift Truck........................................................174 Install the Tyre on the Wheel...............................................................175 INSTALL THE WHEEL AND TYRE......................................................................176 BATTERY SIZE SPECIFICATIONS.........................................................................177 INTRODUCTION........................................................................................178 GENERAL.........................................................................................178 HOW TO MOVE A DISABLED LIFT TRUCK...............................................................178 HOW TO TOW A LIFT TRUCK.........................................................................178 HOW TO PUT A LIFT TRUCK ON BLOCKS...............................................................179 How to Raise the Load Wheels................................................................179 How to Raise The Steer Wheel................................................................180 MAINTENANCE SCHEDULE................................................................................180 MAINTENANCE POINTS..............................................................................180 Maintenance Schedule........................................................................181 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY.......................................................182 CHECKS BEFORE OPERATION.........................................................................182 Hydraulic System............................................................................182 Battery.....................................................................................183 Battery Restraint System....................................................................183 Tyres and Wheels............................................................................184 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................185 Forks.......................................................................................186 Forks, Adjustment ..........................................................................186 Forks, Removal..............................................................................187 Forks, Inspection...........................................................................187 Forks, Installation.........................................................................187 Mast and Lift Chains........................................................................188 Lift Chain Adjustments......................................................................188 CHECK THE OPERATION.............................................................................189 Gauges and Horn.............................................................................189 Control Levers and Pedals...................................................................189 Service Brakes..............................................................................189 Parking Brake...............................................................................190 Steering System.............................................................................190 EVERY 500 HOURS OR THREE MONTHS.....................................................................190 HYDRAULIC TANK BREATHER.........................................................................190 WHEEL NUT TORQUE................................................................................190 TRANSAXLE.......................................................................................190 LIFT SYSTEM OPERATION...........................................................................190 MAST............................................................................................191 LIFT CHAINS.....................................................................................192 FORKS...........................................................................................193 SAFETY LABELS...................................................................................193 BRAKE FLUID.....................................................................................193 OTHER LUBRICATION...............................................................................193 ELECTRICAL INSPECTION...........................................................................193 Contactors..................................................................................193 Motor Brushes...............................................................................196 Parking Brake...............................................................................196 2000 HOURS OR YEARLY................................................................................196 HYDRAULIC SYSTEM................................................................................196 Change the Hydraulic Oil Filter.............................................................196 Check the Hydraulic Oil Strainer............................................................196 Change the Hydraulic Oil....................................................................197 BRAKES..........................................................................................197 Adjust the Parking Brake....................................................................198 TRANSAXLE.......................................................................................198 EVERY 4000 HOURS....................................................................................199 TRANSAXLE (S2 SERIES ONLY)......................................................................199 GENERAL PROCEDURES..................................................................................199 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................199 LIFT SYSTEM.....................................................................................199 TILT SYSTEM.....................................................................................199 HOW TO CHARGE THE BATTERY.......................................................................200 HOW TO CHANGE THE BATTERY.......................................................................201 WHEELS AND TYRES....................................................................................202 GENERAL.........................................................................................202 HOW TO CHANGE THE TYRES.........................................................................202 STEER AND DRIVE WHEELS..........................................................................202 PNEUMATIC TYRES.................................................................................202 Remove the Wheel from the lift truck........................................................202 Tyre Sizes And Presures.....................................................................203 Remove the Tyre from the Wheel..............................................................203 Install The Tyre On The Wheel...............................................................204 PNEUMATIC SHAPED SOLID TYRES....................................................................205 Remove the Wheel from the lift truck........................................................205 Install the Tyre on the Wheel...............................................................205 INSTALL THE WHEEL AND TYRE......................................................................206 BATTERY SIZE SPECIFICATIONS.........................................................................207 INTRODUCTION........................................................................................209 GENERAL.........................................................................................209 HOW TO MOVE A DISABLED LIFT TRUCK...............................................................209 How to Tow a Lift Truck.....................................................................209 HOW TO PUT A LIFT TRUCK ONTO BLOCKS.............................................................210 How to Raise the Load Wheels................................................................210 How to Raise the Steer Wheel................................................................210 MAINTENANCE SCHEDULE................................................................................212 MAINTENANCE SCHEDULE............................................................................213 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY.......................................................214 CHECKS BEFORE OPERATION.........................................................................214 Hydraulic System............................................................................214 Battery.....................................................................................215 Battery Restraint System....................................................................215 Tyres and Wheels............................................................................216 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................217 Forks.......................................................................................218 Forks, Adjustment...........................................................................218 Forks, Removal..............................................................................219 Forks, Inspection...........................................................................219 Forks, Installation.........................................................................219 Mast and Lift Chains........................................................................220 Lift Chain Adjustments......................................................................220 CHECK THE OPERATION.............................................................................221 Gauges and Horn.............................................................................221 Control Levers and Pedals...................................................................221 Service Brakes..............................................................................221 Parking Brakes..............................................................................222 Steering System.............................................................................222 EVERY 350 HOURS OR TWO MONTHS.......................................................................222 HYDRAULIC TANK BREATHER.........................................................................222 WHEEL NUT TORQUE................................................................................222 TRANSAXLE.......................................................................................222 LIFT SYSTEM OPERATION...........................................................................222 MAST............................................................................................223 LIFT CHAINS.....................................................................................224 FORKS...........................................................................................225 SAFETY LABELS...................................................................................225 BRAKE FLUID.....................................................................................225 OTHER LUBRICATION...............................................................................225 ELECTRICAL INSPECTION...........................................................................225 Contactors..................................................................................225 Motor Brushes...............................................................................228 Parking Brake...............................................................................228 2000 HOURS OR YEARLY................................................................................228 HYDRAULIC SYSTEM................................................................................228 Change the Hydraulic Oil Filter.............................................................228 Check the Hydraulic Oil Strainer............................................................228 Change the Hydraulic Oil....................................................................229 BRAKES..........................................................................................229 Adjust the Parking Brake....................................................................229 TRANSAXLE.......................................................................................230 GENERAL PROCEDURES..................................................................................231 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................231 Lift System.................................................................................231 Tilt System.................................................................................231 HOW TO CHECK THE PMT CIRCUIT....................................................................231 HOW TO CHARGE THE BATTERY.......................................................................232 HOW TO CHANGE THE BATTERY.......................................................................233 WHEELS AND TYRES....................................................................................234 GENERAL.........................................................................................234 HOW TO CHANGE THE TYRES.........................................................................235 STEER AND DRIVE WHEELS..........................................................................235 TYRE SIZES AND PRESSURES........................................................................235 PNEUMATIC TYRES.................................................................................235 Remove the Wheel from the Lift Truck........................................................235 Remove the Tyre from the Wheel..............................................................236 Install The Tyre On The Wheel...............................................................236 PNEUMATIC SHAPED SOLID TYRES....................................................................237 Remove the Wheel from the Lift Truck........................................................237 Install the Tyre on the Wheel...............................................................238 INSTALL THE WHEEL AND TYRE......................................................................239 BATTERY SIZE SPECIFICATIONS.....................................................................240 INTRODUCTION........................................................................................242 GENERAL.........................................................................................242 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................242 REPAIRS.............................................................................................243 FORKS...........................................................................................243 Removal.....................................................................................243 Installation................................................................................244 CARRIAGES.......................................................................................244 Removal.....................................................................................244 Repairs.....................................................................................245 Installation................................................................................245 MASTS...........................................................................................247 Removal.....................................................................................247 Disassembly.................................................................................248 Cleaning and Inspection.....................................................................253 Assembly....................................................................................256 Installation................................................................................258 LIFT CYLINDERS..................................................................................258 Removal.....................................................................................258 Disassembly.................................................................................259 Assembly....................................................................................259 Installation................................................................................259 HEADER HOSE ARRANGEMENTS........................................................................262 Installation................................................................................262 CHECKS AND ADJUSTMENTS..............................................................................271 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................271 Check The Lift Cylinders For Leaks..........................................................271 Check The Tilt Cylinders For Leaks..........................................................271 ADJUST THE TILT CYLINDERS.......................................................................271 ADJUST THE LIFT CHAINS..........................................................................272 ADJUST THE MAST.................................................................................273 ADJUST THE CARRIAGE.............................................................................274 TROUBLESHOOTING.....................................................................................275 INTRODUCTION........................................................................................279 GENERAL.........................................................................................279 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................279 REPAIRS.............................................................................................280 FORKS...........................................................................................280 Removal.....................................................................................280 Installation................................................................................281 CARRIAGES.......................................................................................281 Removal.....................................................................................281 Repairs.....................................................................................282 Installation................................................................................282 MASTS...........................................................................................284 Removal.....................................................................................284 Disassembly.................................................................................285 Cleaning and Inspection.....................................................................290 Assembly....................................................................................293 Installation................................................................................295 LIFT CYLINDERS..................................................................................295 Removal.....................................................................................295 Disassembly.................................................................................296 Assembly....................................................................................296 Installation................................................................................296 HEADER HOSE ARRANGEMENTS........................................................................299 Installation................................................................................299 CHECKS AND ADJUSTMENTS..............................................................................308 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.....................................................308 Check The Lift Cylinders For Leaks..........................................................308 Check The Tilt Cylinders For Leaks..........................................................308 ADJUST THE TILT CYLINDERS.......................................................................308 ADJUST THE LIFT CHAINS..........................................................................309 ADJUST THE MAST.................................................................................310 ADJUST THE CARRIAGE.............................................................................311 TROUBLESHOOTING.....................................................................................312 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................315 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................................315 LIFT CYLINDERS......................................................................................318 GENERAL.........................................................................................318 DESCRIPTION.....................................................................................318 Lowering Control Valve......................................................................318 Cylinders (General).........................................................................321 Cylinders (H520-620B,H700-800A).............................................................323 Cylinders (H360-460B).......................................................................324 Cylinders (Two-Speed).......................................................................324 REPAIRS.............................................................................................325 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..........................................325 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....325 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.....................329 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...............327 DISASSEMBLY.....................................................................................327 ASSEMBLY........................................................................................329 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...................................................329 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast....329 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead............329 CHEVRON PACKING.................................................................................330 LIFT CYLINDERS FOR VISTA MASTS......................................................................333 DESCRIPTION.....................................................................................333 Lowering Control Valve......................................................................335 REMOVAL.........................................................................................336 DISASSEMBLY.....................................................................................336 ASSEMBLY........................................................................................336 INSTALLATION....................................................................................337 Main Lift Cylinders.........................................................................337 Free-Lift Cylinders.........................................................................337 CHECKS AND ADJUSTMENTS..............................................................................338 CHECK FOR LEAKS IN LIFT SYSTEM..................................................................338 TROUBLESHOOTING.....................................................................................339 SPECIFICATIONS......................................................................................340 INTRODUCTION........................................................................................341 General.........................................................................................341 DESCRIPTION.........................................................................................341 Diagnostic Control Card.........................................................................341 Status Codes................................................................................343 Hand Set........................................................................................343 Instrument Panel Display........................................................................344 Hourmeter Functions.........................................................................344 Battery Indicator Functions.................................................................344 Control Card Connections........................................................................345 CHECKS AND ADJUSTMENTS..............................................................................351 General.........................................................................................351 Function Codes..............................................................................351 Connecting The Control Card For Bench Checks And Adjustments................................352 Connecting The Hand Set To A Control Card Installed In A Lift Truck.........................353 Checking And Adjusting Function Settings........................................................353 General.....................................................................................353 How To Connect And Check Hand Set ..........................................................353 How To Check And Adjust Functions...........................................................353 Function Descriptions.......................................................................354 Traction Control Cards (EV-100/200 LXT-LX)..................................................354 Pump Control Card (EV-100/200 LXP)..........................................................358 Dual Motor Traction Control Card (EV-100 LXM)...............................................359 Function Tables.................................................................................362 REPAIRS.............................................................................................375 General.........................................................................................375 Control Card Plugs..............................................................................375 TROUBLESHOOTING.....................................................................................376 General.........................................................................................376 WIRING SCHEMATIC WITH SCR CONTROLLED LIFT PUMP......................................................411 WIRING DIAGRAM WITH SCR CONTROLLED LIFT PUMP........................................................415 OPTIONAL WIRING WITH SCR CONTROLLED LIFT PUMP.......................................................416 WIRING SCHEMATIC WITH TMM MODULE....................................................................419 WIRING DIAGRAM WITH TMM MODULE......................................................................423 OPTIONAL WIRING WITH TMM MODULE.....................................................................424 WIRING SCHEMATIC WITH CONTACTOR CONTROLLED LIFT PUMP................................................427 WIRING DIAGRAM WITH CONTACTOR CONTROLLED LIFT PUMP..................................................431 OPTIONAL WIRING WITH CONTACTOR CONTROLLED LIFT PUMP.................................................433 OPTIONAL MAIN LIGHTS WIRING.........................................................................435 CABLE DETAILS.......................................................................................439 ELECTRICAL ARRANGEMENT WITH SCR CONTROLLED LIFT PUMP................................................440 ELECTRICAL ARRANGEMENT WITH CONTACTOR CONTROLLED LIFT PUMP..........................................441 HYDRAULIC SYSTEM ARRANGEMENT........................................................................442 HYDRAULIC SCHEMATIC.................................................................................443 INTRODUCTION........................................................................................445 GENERAL.........................................................................................445 DESCRIPTION.....................................................................................445 OPERATION.......................................................................................445 REPAIRS.............................................................................................446 STEERING HOUSING ...............................................................................446 Removal And Disassembly ........................................................................446 Cleaning .......................................................................................448 Assembly and Installation.......................................................................448 STEERING CONTROL UNIT...........................................................................448 Removal.....................................................................................448 Disassembly.................................................................................448 Cleaning....................................................................................449 Assembly....................................................................................449 Installation................................................................................449 CHECKS AND ADJUSTMENTS..............................................................................453 REMOVE AIR FROM THE SYSTEM......................................................................453 TROUBLESHOOTING.....................................................................................453 INTRODUCTION........................................................................................454 GENERAL.........................................................................................454 OPERATION.......................................................................................454 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................455 DESCRIPTION.....................................................................................455 Removal.....................................................................................455 Installation................................................................................457 POWER STEERING PUMP AND MOTOR...................................................................458 DESCRIPTION.................................................................................458 Removal.................................................................................459 Installation............................................................................460 REPAIRS.....................................................................................461 Disassembly.............................................................................461 Assembly................................................................................461 STEERING AXLE COMPONENTS............................................................................462 GENERAL.........................................................................................462 WHEEL AND TYRE ASSEMBLY.........................................................................462 Removal.....................................................................................462 Installation................................................................................462 WHEEL HUB ASSEMBLY..............................................................................462 Removal.....................................................................................462 Installation................................................................................463 STEERING AXLE ASSEMBLY..........................................................................463 OLD STEERING SYSTEM.............................................................................463 Removal.....................................................................................463 Installation................................................................................464 ROTARY ACTUATOR (OLD SYSTEM ONLY)...............................................................465 Removal.....................................................................................465 Installation................................................................................466 Disassembly.................................................................................466 Assembly....................................................................................467 NEW STEERING SYSTEM.............................................................................468 Disassembly.................................................................................468 Cleaning ...................................................................................469 Assembly....................................................................................469 CHECKS AND ADJUSTMENTS..............................................................................471 AIR IN THE SYSTEM...............................................................................471 Check the Operation.........................................................................471 Steering Pressure...........................................................................471 TROUBLESHOOTING.....................................................................................472 INTRODUCTION........................................................................................478 GENERAL.........................................................................................478 DESCRIPTION.....................................................................................478 REPAIRS.............................................................................................478 REMOVAL.........................................................................................478 DISASSEMBLY.....................................................................................478 CLEANING........................................................................................478 ASSEMBLY........................................................................................478 Tilt Cylinders for the XM and XMS Models....................................................478 Tilt Cylinders with O-Ring or Single Lip Seals..............................................480 Tilt Cylinders for H700-800A and Early Model H700-920B......................................480 INSTALLATION....................................................................................480 Tilt Cylinders with Chevron Packing.........................................................480 CHECKS AND ADJUSTMENTS..............................................................................484 CHECK THE TILT CYLINDERS FOR LEAKS..............................................................484 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.........................................484 TROUBLESHOOTING.....................................................................................487 INTRODUCTION........................................................................................492 GENERAL.........................................................................................492 LUBRICATION.....................................................................................492 REPAIRS.............................................................................................493 REMOVAL.........................................................................................493 INSPECTION......................................................................................494 INSTALLATION....................................................................................494 S2 SERIES TRANSAXLE.................................................................................495 DISASSEMBLY.....................................................................................495 ASSEMBLY........................................................................................496 General.....................................................................................496 Ring Gear Installation......................................................................496 Intermediate Shaft Installation.............................................................496 Axle Shaft Installation.....................................................................497 Pinion Gear Installation....................................................................497 Final Assembly..............................................................................500 S1 SERIES TRANSAXLE.................................................................................502 DISASSEMBLY.....................................................................................502 ASSEMBLY........................................................................................502 TROUBLESHOOTING.....................................................................................506 WHEELS AND TYRES....................................................................................508 MOTORS (DUAL VOLTAGE 36/48).........................................................................508 MAST TILT PERFORMANCE...............................................................................508 MAST SPEEDS 19cc PUMP 1 and 2 SPEED CONTACTOR.......................................................509 MAST SPEEDS 19cc PUMP TRANSISTOR CONTROL............................................................510 MAST SPEEDS 12cc PUMP 1 and 2 SPEED CONTACTOR.......................................................511 MAST SPEEDS 12cc PUMP TRANSISTOR CONTACTOR..........................................................512 MAST/TILT DRIFT SPEEDS..............................................................................512 HYDRAULIC SYSTEM....................................................................................513 TORQUE SPECIFICATIONS...............................................................................513 ACCELERATOR POTENTIOMETER CHECKS....................................................................514 ADJUSTMENTS, EV 100 LX TRACTION CARD................................................................515 SX/SR Traction Controller Settings - Standard.......................................................516 SX/SR Traction Controller Settings - Energy Option..................................................517 SX/SR Traction Controller Settings - With or Without Auto Regen.....................................517 ADJUSTMENTS, EV 100 LX PUMP CARD....................................................................518 SX/SR Lift Pump Controller Settings.................................................................519 BATTERY SIZE SPECIFICATIONS - TYPE: LEAD ACID BATTERY ..............................................520
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
