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Hyster Forklift J25 35B, J30BS service manual – PDF DOWNLOAD
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Hyster Forklift J25 35B, J30BS service manual
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Hyster Forklift J25 35B, J30BS service manual
Language : English
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HYSTER FORKLIFT J25 35B, J30BS SERVICE MANUAL – PDF DOWNLOAD:
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Hyster Forklift J25 35B, J30BS service manual
Table of Contents:
Hyster Forklift J25 35B, J30BS 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................................................................................................. 7 CHECKS AND ADJUSTMENTS................................................................................................................ 9 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, EARLY MODELS........................................................................... 9 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.............................................................................. 9 Reset Potentiometer........................................................................................................... 9 Specific Gravity Alarm........................................................................................................ 10 BATTERY INDICATORS WITHOUT LIFT INTERRUPT, LATER MODELS........................................................................... 11 BATTERY INDICATORS WITH LIFT INTERRUPT, EARLY MODELS.............................................................................. 11 Reset Potentiometer........................................................................................................... 11 Discharge Potentiometer....................................................................................................... 11 LED DISPLAY WITH LIFT INTERRUPT................................................................................................... 12 CHECKING CURTIS 933-1 METER....................................................................................................... 12 Reset Check................................................................................................................... 12 Discharge Check............................................................................................................... 13 Lockout Check................................................................................................................. 13 LED's Do Not Illuminate....................................................................................................... 14 Hourmeter Check............................................................................................................... 14 Hour Glass Icon............................................................................................................... 14 ADJUSTMENT OF CURTIS 933-1 METER.............................................................................................. 14 CHECKING CURTIS 1215 BATTERY INDICATOR........................................................................................ 14 ADJUSTING CURTIS 1215 BATTERY INDICATOR....................................................................................... 15 Voltage Selection......................................................................................................... 16 ADJUSTING BDI OF SEM DISPLAY PANEL............................................................................................ 17 REPAIRS........................................................................................................................... 17 BATTERY INDICATORS............................................................................................................ 17 Replacement............................................................................................................... 17 CONTROLLER FOR THE BATTERY INDICATOR.......................................................................................... 17 Replacement............................................................................................................... 17 DISPLAY PANEL COMPONENTS...................................................................................................... 17 REPLACING SEM DISPLAY PANEL................................................................................................... 17 SEM Display Panel REMOVAL..................................................................................................... 19 Removal And Replacement................................................................................................... 19 INTRODUCTION.......................................................................................................................... 21 General........................................................................................................................... 21 Description....................................................................................................................... 21 REPAIRS............................................................................................................................... 22 Service Brakes.................................................................................................................... 22 Parking Brake..................................................................................................................... 24 Seat Brake........................................................................................................................ 26 CHECKS AND ADJUSTMENTS................................................................................................................ 28 Removing Air From The Service Brakes ............................................................................................. 28 Brake Pedal Adjustment............................................................................................................ 28 Adjustment Of The Parking Brake Linkage........................................................................................... 28 Adjustment Of The Seat Brake...................................................................................................... 28 Adjustment Of The Friction Pads................................................................................................... 29 TROUBLESHOOTING....................................................................................................................... 30 INTRODUCTION.......................................................................................................................... 37 MAGNETISM............................................................................................................................. 37 MAGNETISM AND PERMANENT MAGNETS................................................................................................... 37 ELECTROMAGNETIC FIELDS............................................................................................................ 37 ELECTROMAGNETS.................................................................................................................... 38 ELECTROMAGNETIC INDUCTION......................................................................................................... 39 MAGNETIC FORCE ON A CONDUCTOR..................................................................................................... 39 BASIC MOTORS.......................................................................................................................... 40 MOTOR OPERATION................................................................................................................... 40 COMMUTATION PRINCIPLE............................................................................................................. 41 DIRECTION OF MOTOR ROTATION....................................................................................................... 41 MOTOR SPEED....................................................................................................................... 41 MOTOR TORQUE...................................................................................................................... 42 COUNTER ELECTROMOTIVE FORCE....................................................................................................... 42 TYPICAL MOTOR..................................................................................................................... 42 TYPES OF MOTORS................................................................................................................... 42 Permanent–Magnet.............................................................................................................. 42 Series Wound.................................................................................................................. 43 Parallel or Shunt Wound....................................................................................................... 44 Compound Wound................................................................................................................ 44 MOTOR INSULATION CLASS............................................................................................................ 45 STORAGE........................................................................................................................... 45 HANDLING.......................................................................................................................... 45 BREAK–IN OPERATION................................................................................................................ 45 CLEANING.......................................................................................................................... 46 BASIC REPAIR GUIDELINES........................................................................................................... 46 BEARINGS, SEALS AND LUBRICATION................................................................................................... 47 BRUSHES AND BRUSH HOLDERS......................................................................................................... 47 ARMATURE.......................................................................................................................... 48 COMMUTATOR........................................................................................................................ 48 Description................................................................................................................... 48 SATISFACTORY SURFACE.............................................................................................................. 49 STREAKING AND THREADING SURFACE................................................................................................... 50 GROOVING ON SURFACE............................................................................................................... 51 COPPER DRAG ON SURFACE............................................................................................................ 53 OVERHEATING....................................................................................................................... 53 FIELD ASSEMBLY.................................................................................................................... 55 INSPECTION CHECKLIST.............................................................................................................. 55 CHECKING AND REPLACING MOTOR BRUSHES.............................................................................................. 55 Inspecting Brushes............................................................................................................ 55 INSPECT THE COMMUTATOR............................................................................................................ 56 REPLACING BRUSHES................................................................................................................. 56 SEATING BRUSHES (STONING PROCEDURE)............................................................................................... 56 CHECK THE MOTORS FOR OPENS, GROUNDS AND SHORTS.................................................................................... 57 Check The Motor For Opens..................................................................................................... 57 Check The Motor For Grounds................................................................................................... 57 Check The Motor For Shorts.................................................................................................... 57 COMMUTATOR INSPECTION............................................................................................................. 59 POLISHING COMMUTATOR.............................................................................................................. 60 TURNING COMMUTATOR................................................................................................................ 60 UNDERCUTTING COMMUTATOR........................................................................................................... 60 SLOT RAKING AND BRUSHING COMMUTATOR............................................................................................... 60 FIGURE 1. EV-100 SCHEMATIC DIAGRAM, DUAL MOTOR CONTROLLER............................................................................. 62 FIGURE 2. EV-100 WIRE DIAGRAM, DUAL MOTOR CONTROLLER.................................................................................. 64 FIGURE 3. EV-100 WIRE DIAGRAM, CONTROL SWITCHES....................................................................................... 66 FIGURE 4. EV-100 "LX" SCHEMATIC DIAGRAM, DUAL MOTOR CONTROLLER........................................................................ 68 FIGURE 5. EV-100 "LX" WIRE DIAGRAM, DUAL MOTOR CONTROLLER............................................................................. 70 FIGURE 6. EV-100 "LX" WIRE DIAGRAM, CONTROL SWITCHES.................................................................................. 72 FIGURE 7. CABLE DIAGRAM............................................................................................................... 74 FIGURE 8. ARRANGEMENT, ELECTRIC CONTROL............................................................................................... 75 FIGURE 9. HYDRAULIC SYSTEM (EARLY PRODUCTION LIFT TRUCKS)............................................................................. 76 FIGURE 10. HYDRAULIC SCHEMATIC (EARLY PRODUCTION LIFT TRUCKS)......................................................................... 77 FIGURE 11. HYDRAULIC SYSTEM (LATER PRODUCTION LIFT TRUCKS)............................................................................ 78 FIGURE 12. HYDRAULIC SCHEMATIC (LATER PRODUCTION LIFT TRUCKS)......................................................................... 79 ELECTRICAL CHECKS AND ADJUSTMENTS FOR SitDrive) ELECTRICAL LIFT TRUCKS................................................................ 80 GENERAL........................................................................................................................... 80 CONTROL AND POWER FUSES........................................................................................................... 85 CONTROL CARD ADJUSTMENTS.......................................................................................................... 86 Adjusting Creep Speed, "CREEP'................................................................................................ 88 Adjusting Controlled Acceleration, "C/A" ..................................................................................... 88 Adjusting Current Limit, "C/L"................................................................................................ 89 Adjust "1A TIME".............................................................................................................. 90 Adjust 1A Drop Out, "1A D.O".................................................................................................. 92 Adjust Plugging, "PLUG"....................................................................................................... 92 Ramp Start.................................................................................................................... 92 Adjust Field Weakening Pick Up and Drop Out, "F.W.P.U." And "F.W.D.O."........................................................ 92 Adjust "REGEN C/L" (Current Limit)............................................................................................ 93 Adjust "REGEN D.O." (Drop Out)................................................................................................ 93 PROPORTIONAL CONTROL (J25-35A Only)............................................................................................... 96 SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS........................................................................................... 97 SCR CONTROL, SINGLE PUMP MOTOR.................................................................................................... 97 Accelerator Card (E-20-100B, J40-60AS Only)................................................................................... 98 Circuit Description For Accelerator Card Used With A Seat Switch.............................................................. 99 Accelerator "START" (IC3).....................................................................................................100 Accelertor "1A TIME" (IC2)....................................................................................................100 Circuit Description For Accelerator Card Used With A Seat Brake...............................................................100 Accelerator "START" (IC3).....................................................................................................101 Accelerator "1A TIME" (IC1 and IC2)...........................................................................................101 CHECK THE ACCELERTOR CARD.....................................................................................................101 ADJUSTING THE ACCELERATOR CARD................................................................................................101 THE POTENTIOMETERS AND CONTOL SWITCHES............................................................................................101 Steering Potentiometer (J25-35A Only).........................................................................................101 Accelerator Potentiometer And Start Switch (E20-120XL And J25-60XL Only)......................................................103 Accelerator Potentiometer And Direction Switch................................................................................104 Adjusting Start Switch........................................................................................................105 "FORWARD" And "REVERSE" Switch (MONOTROL) (Earlier Production Lift Trucks)....................................................105 Direction Switches (MONOTROL) (Later Production Lift Trucks)..................................................................106 "FORWARD" And "REVERSE" Switch (Steering Column)..............................................................................107 Hydraulic Pump Switch.........................................................................................................107 Replace The Key Switch........................................................................................................107 Adjust The Seat Switch........................................................................................................107 Adjust The Brake Switch.......................................................................................................108 Parking Brake Switch..........................................................................................................108 Rocker Switch.................................................................................................................109 HYDRAULIC PUMP SOFT START (E100-120B Only) (72/80 Volt Only)......................................................................110 INTRODUCTION..........................................................................................................................111 General...........................................................................................................................111 SRO CIRCUIT AND PMT CIRCUIT (TRACTION CIRCUIT)........................................................................................112 Static Return To Off (SRO) Circuit................................................................................................112 Pulse Monitor Trip (PMT)..........................................................................................................113 Sequence of Operation.............................................................................................................113 Checking For Correct Operation....................................................................................................114 TROUBLESHOOTING.......................................................................................................................114 General Procedures................................................................................................................115 Fault Guide.......................................................................................................................117 1. The Direction Contactors Will Not Close For Operation In Either Direction...............................................117 2. Lift Truck will Not Move In Either Direction. The Directino Contactors Close and Then Immediately Open (PMT Fault).....120 3. Lift Truck will Not Move in Either Direction. The Drection Contactors Close Normally (No PMT Fault)....................122 4. Traction Circuit Operates Normally Only In One Direction................................................................124 5. One Traction Motor Does Not Operate. The Other Traction Motor Operates Normally........................................125 6. One Traction Motor Will Not Operate In One Direction. The Lift Truck Operates Normally In The Other Direction..........126 7. Direction Contactors Close Normally. The Lift Truck Has Only Low Power Or Moves Slowly.................................127 8. Contactor 1A Will Not Energize. The Other Operations Of The Lift Truck Are Normal......................................128 9. Plugging Problems.......................................................................................................129 10. Steering Problems........................................................................................................129 INTRODUCTION..........................................................................................................................130 General...........................................................................................................................130 CONTROL SWITCHES......................................................................................................................131 Steering Switches.................................................................................................................131 MONOTROL and Accelerator Pedal Adjustments........................................................................................132 Later Production MONTROL..........................................................................................................133 FORWARD and REVERSE Switch (Steering Column)......................................................................................135 Brake Switch......................................................................................................................136 Seat Switch.......................................................................................................................136 Hydraulic Pump Switches...........................................................................................................136 EV-100 DUAL MOTOR CONTROLLER..........................................................................................................137 Fuses.............................................................................................................................137 Control Card......................................................................................................................138 Checking An SCR...................................................................................................................140 The OFF Circuit For SCR 1.........................................................................................................141 Diodes D3 and D4..................................................................................................................143 Motor Current Sensor..............................................................................................................144 The Electronic Driver Module......................................................................................................144 Contactors........................................................................................................................146 Contactor Repair..................................................................................................................147 Control Card Adjustments..........................................................................................................147 EV-100E MOTOR CONTROLLER, DESCRIPTION AND OPERATION...................................................................................151 GENERAL...........................................................................................................................151 ELECTRONIC SPEED CONTROLS.........................................................................................................152 The Silicon Controlled Rectifier (SCR)........................................................................................152 A Motor Circuit That Operates With Pulses.....................................................................................153 Traction Circuit..............................................................................................................155 Hydraulic Motor Circuit.......................................................................................................155 The SCR 1 "OFF" Circuit.......................................................................................................155 INDUCTION CURRENT FROM THE MOTOR..................................................................................................157 THE CONTROL CARD..................................................................................................................162 Pulse Monitor Trip (PMT) (Traction Circuit Only)..............................................................................163 SRO Circuit (Traction Circuit Only)...........................................................................................164 Control Card Adjustments (Traction Circuit)...................................................................................164 Accelerator Control...........................................................................................................168 Dual Motor "Plugging" (J25-35B)...............................................................................................168 SCR CONTROL (HYDRAULIC PUMP MOTOR)................................................................................................169 CONTACTORS AND ELECTRONIC DRIVERS (TRACTION CIRCUIT)..............................................................................170 The Electronic Drivers........................................................................................................170 Contactors....................................................................................................................171 CIRCUIT PROTECTION................................................................................................................172 Current Limit.................................................................................................................172 Thermal Protection............................................................................................................172 Suppressors...................................................................................................................172 Traction Circuit Fuse.........................................................................................................173 SEQUENCE OF OPERATION.................................................................................................................173 INTRODUCTION..........................................................................................................................186 General...........................................................................................................................186 DESCRIPTION...........................................................................................................................186 Diagnostic Control Card...........................................................................................................186 Status Codes..................................................................................................................188 Hand Set..........................................................................................................................188 Instrument Panel Display..........................................................................................................189 Hourmeter Functions...........................................................................................................189 Battery Indicator Functions...................................................................................................189 Control Card Connections..........................................................................................................190 CHECKS AND ADJUSTMENTS................................................................................................................196 General...........................................................................................................................196 Function Codes................................................................................................................196 Connecting The Control Card For Bench Checks And Adjustments..................................................................197 Connecting The Hand Set To A Control Card Installed In A Lift Truck...........................................................198 Checking And Adjusting Function Settings..........................................................................................198 General.......................................................................................................................198 How To Connect And Check Hand Set ............................................................................................198 How To Check And Adjust Functions.............................................................................................198 Function Descriptions.........................................................................................................199 Traction Control Cards (EV-100/200 LXT-LX)....................................................................................199 Pump Control Card (EV-100/200 LXP)............................................................................................203 Dual Motor Traction Control Card (EV-100 LXM).................................................................................204 Function Tables...................................................................................................................207 REPAIRS...............................................................................................................................220 General...........................................................................................................................220 Control Card Plugs................................................................................................................220 TROUBLESHOOTING.......................................................................................................................221 General...........................................................................................................................221 INTRODUCTION..........................................................................................................................256 General...........................................................................................................................256 Description.......................................................................................................................256 DISASSEMBLY AND ASSEMBLY..............................................................................................................257 Overhead Guard....................................................................................................................257 Hood and Seat Assembly............................................................................................................257 Counterweight.....................................................................................................................258 Hydraulic Tank Repairs............................................................................................................258 Decal Replacement.................................................................................................................260 INTRODUCTION..........................................................................................................................262 General...........................................................................................................................262 HYDRAULIC SYSTEM......................................................................................................................262 Hydraulic System (Early Production Lift Trucks)...................................................................................262 Hydraulic System (Later Production Lift Trucks)...................................................................................265 MAIN CONTROL VALVE....................................................................................................................267 Main Control Valve (Early Production Lift Trucks).................................................................................268 Repairs...........................................................................................................................272 Main Control Valve (Later Production Lift Trucks).................................................................................275 Repairs...........................................................................................................................279 Checks and Adjustments............................................................................................................281 HYDRAULIC PUMP........................................................................................................................282 Description.......................................................................................................................282 Repairs...........................................................................................................................282 TROUBLESHOOTING (HYDRAULIC PUMP)......................................................................................................285 TROUBLESHOOTING (MAIN CONTROL VALVE)..................................................................................................285 SPECIFICATIONS........................................................................................................................286 INTRODUCTION..........................................................................................................................287 GENERAL...........................................................................................................................287 LEAD-ACID BATTERIES...............................................................................................................287 SPECIFIC GRAVITY..................................................................................................................288 CHEMICAL REACTION IN A CELL.......................................................................................................288 ELECTRICAL TERMS..................................................................................................................289 HOW TO SELECT THE BATTERY.........................................................................................................289 VOLTAGE OF A BATTERY..............................................................................................................289 THE BATTERY AS A COUNTERWEIGHT....................................................................................................290 BATTERY RATINGS...................................................................................................................290 Kilowatt-Hours................................................................................................................291 BATTERY MAINTENANCE...................................................................................................................291 SAFETY PROCEDURES.................................................................................................................291 MAINTENCE RECORDS.................................................................................................................292 THE NEW BATTERY...................................................................................................................292 HOW TO CLEAN THE BATTERY..........................................................................................................293 HOW TO ADD WATER..................................................................................................................293 THE HYDROMETER....................................................................................................................294 BATTERY TEMPERATURE...............................................................................................................294 CHARGING THE BATTERY..............................................................................................................295 Types Of Battery Charges......................................................................................................296 Methods Of Charging...........................................................................................................297 Troubleshooting The Charger...................................................................................................297 How to Know When The Battery Is Fully Charged.................................................................................298 WHERE TO CHARGE THE BATTERIES.....................................................................................................298 Equipment Needed..............................................................................................................298 BATTERY CONNECTORS................................................................................................................299 BATTERY CARE......................................................................................................................299 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..........................................................................................301 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................................301 LIFT CYLINDERS........................................................................................................................304 GENERAL...........................................................................................................................304 DESCRIPTION.......................................................................................................................304 Lowering Control Valve........................................................................................................304 Cylinders (General)...........................................................................................................307 Cylinders (H520-620B,H700-800A)...............................................................................................309 Cylinders (H360-460B).........................................................................................................310 Cylinders (Two-Speed).........................................................................................................310 REPAIRS...............................................................................................................................311 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST............................................................................311 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast......................................311 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.......................................................315 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.................................................313 DISASSEMBLY.......................................................................................................................313 ASSEMBLY..........................................................................................................................315 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.....................................................................................315 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast......................................315 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead..............................................315 CHEVRON PACKING...................................................................................................................316 LIFT CYLINDERS FOR VISTA MASTS........................................................................................................319 DESCRIPTION.......................................................................................................................319 Lowering Control Valve........................................................................................................321 REMOVAL...........................................................................................................................322 DISASSEMBLY.......................................................................................................................322 ASSEMBLY..........................................................................................................................322 INSTALLATION......................................................................................................................323 Main Lift Cylinders...........................................................................................................323 Free-Lift Cylinders...........................................................................................................323 CHECKS AND ADJUSTMENTS................................................................................................................324 CHECK FOR LEAKS IN LIFT SYSTEM....................................................................................................324 TROUBLESHOOTING.......................................................................................................................325 SPECIFICATIONS........................................................................................................................326 INTRODUCTION..........................................................................................................................327 GENERAL...........................................................................................................................327 DESCRIPTION.......................................................................................................................327 REPAIRS...............................................................................................................................327 REMOVAL AND DISASSEMBLY...........................................................................................................327 CLEANING .........................................................................................................................328 ASSEMBLY..........................................................................................................................328 CHECKS AND ADJUSTMENTS................................................................................................................328 CHECKS............................................................................................................................328 INTRODUCTION..........................................................................................................................329 GENERAL...........................................................................................................................329 SERIAL NUMBER DATA................................................................................................................329 HOW TO MOVE A DISABLED LIFT TRUCK.................................................................................................329 How To Tow A Lift Truck.......................................................................................................329 RELEASE THE SEAT BRAKE ON A DISABLED LIFT TRUCK...................................................................................330 HOW TO PUT A LIFT TRUCK ON BLOCKS.................................................................................................331 HOW TO RAISE THE DRIVE TIRES......................................................................................................331 How to Raise the Steering Tires...............................................................................................331 MAINTENANCE SCHEDULE..................................................................................................................332 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY.........................................................................................334 CHECKS BEFORE OPERATION...........................................................................................................334 HOW TO MAKE CHECKS WITH THE KEY OFF...............................................................................................334 Tires And Wheels..............................................................................................................334 Forks.........................................................................................................................335 Fork Adjustment...............................................................................................................335 Hook Fork, Removal............................................................................................................335 Hook Fork, Installation.......................................................................................................336 Inspection Of Mast, Forks, And Lift Chains....................................................................................336 Safety Labels.................................................................................................................337 Operator Restraint System.....................................................................................................338 Check The Operation...........................................................................................................338 Battery Restraint System......................................................................................................338 Battery.......................................................................................................................339 Hydraulic System..............................................................................................................339 HOW TO MAKE CHECKS WITH THE KEY ON................................................................................................340 Gauges And Horn...............................................................................................................340 Steering System...............................................................................................................340 Service Brakes................................................................................................................340 Parking Brake.................................................................................................................340 Control Levers And Pedals.....................................................................................................341 Lift System Operation.........................................................................................................341 EVERY 350 HOURS OR TWO MONTHS.........................................................................................................342 HYDRAULIC TANK BREATHER...........................................................................................................342 TRANSAXLE.........................................................................................................................342 WHEEL NUT TORQUE..................................................................................................................342 MAST..............................................................................................................................342 LIFT CHAINS.......................................................................................................................343 Check for Wear................................................................................................................343 Lubrication...................................................................................................................344 FORKS.............................................................................................................................344 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................................345 SEAT BRAKE........................................................................................................................346 BRAKE FLUID.......................................................................................................................346 OTHER LUBRICATION.................................................................................................................346 ELECTRICAL INSPECTION.............................................................................................................346 CONTACTORS........................................................................................................................346 MOTOR BRUSHES.....................................................................................................................347 2000 HOURS OR YEARLY..................................................................................................................348 HYDRAULIC SYSTEM..................................................................................................................348 CHANGE THE OIL FILTER.............................................................................................................348 CHANGE THE HYDRAULIC OIL..........................................................................................................348 TRANSAXLE.........................................................................................................................348 STEERING SYSTEM...................................................................................................................349 Manual Steering...............................................................................................................349 Power Steering................................................................................................................349 BRAKES............................................................................................................................349 CONTACTORS........................................................................................................................350 LIFT CHAINS.......................................................................................................................350 GENERAL PROCEDURES....................................................................................................................351 HOW TO CHARGE THE BATTERY.........................................................................................................351 HOW TO CHANGE THE BATTERY.........................................................................................................352 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.......................................................................................353 Check the Lift Cylinders for Leaks............................................................................................353 Check the Tilt Cylinders for Leaks............................................................................................353 WELDING REPAIRS...................................................................................................................354 CHANGES TO THE OVERHEAD GUARD.....................................................................................................354 LIFT CHAIN ADJUSTMENTS............................................................................................................354 HOW TO CHECK THE PMT CIRCUIT......................................................................................................355 WHEELS AND TIRES..................................................................................................................355 How To Change A Solid Rubber (Press-on) Tire..................................................................................356 How To Repair A Pneumatic Tire................................................................................................356 How To Remove A Wheel From The Lift Truck.....................................................................................357 How To Remove Tire From The Wheel.............................................................................................357 How To Install The Tire On The Wheel..........................................................................................358 Add Air To The Tires..........................................................................................................359 How To Install The Wheel......................................................................................................359 Solid Rubber Tires That Look Like Pneumatic Tires.............................................................................359 Remove The Wheels From The Lift Truck.........................................................................................359 Remove The Tire From The Wheel................................................................................................359 Install The Tire On The Wheel.................................................................................................359 REFERENCE TABLE.......................................................................................................................362 INTRODUCTION..........................................................................................................................363 NOMENCLATURE, THREADS.............................................................................................................363 STRENGTH IDENTIFICATION...........................................................................................................364 TABLE 1. BOLTS AND SCREWS.............................................................................................................364 TABLE 2. STUDS AND NUTS...............................................................................................................365 TABLE 3. TORQUE NUTS..................................................................................................................366 TABLE 4. TORQUE NUTS WITH NYLON INSERT................................................................................................367 TABLE 5. TORQUE VALUES FOR INCH FASTENERS.............................................................................................368 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS...........................................................................................369 STEERING CONTROL UNIT.................................................................................................................372 GENERAL...........................................................................................................................372 DESCRIPTION.......................................................................................................................372 Control Valve Section.........................................................................................................372 Metering Section..............................................................................................................372 DISASSEMBLY AND INSPECTION........................................................................................................374 ASSEMBLY..........................................................................................................................384 TROUBLESHOOTING.......................................................................................................................398 INTRODUCTION..........................................................................................................................399 GENERAL...........................................................................................................................399 DESCRIPTION.......................................................................................................................399 OPERATION.........................................................................................................................399 REPAIRS...............................................................................................................................399 STEERING WHEEL AND COLUMN ASSEMBLY................................................................................................399 TYPE "A" STEERING COLUMN ASSEMBLY.................................................................................................401 Removal And Disassembly.......................................................................................................401 Assembly And Installation.....................................................................................................401 TYPE "A" STEERING COLUMN..........................................................................................................402 TYPE "A" STEERING COLUMN..........................................................................................................403 TYPE "B" STEERING COLUMN..........................................................................................................404 Removal And Disassembly.......................................................................................................404 Assembly And Installation.....................................................................................................404 TYPE "B" STEERING COLUMN..........................................................................................................405 Disassembly of Steering Control Unit..........................................................................................406 Cleaning of Steering Control Unit.............................................................................................406 Assembly of Steering Control Unit.............................................................................................408 CHECKS AND ADJUSTMENTS................................................................................................................411 REMOVE AIR FROM THE SYSTEM........................................................................................................411 TROUBLESHOOTING.......................................................................................................................412 INTRODUCTION..........................................................................................................................413 GENERAL...........................................................................................................................413 DESCRIPTION.......................................................................................................................413 STEERING WHEEL AND COLUMN ASSEMBLY....................................................................................................415 STEERING WHEEL AND HORN...........................................................................................................415 Removal.......................................................................................................................415 Installation..................................................................................................................417 STEERING CONTROL UNIT.............................................................................................................417 Removal ......................................................................................................................417 Installation..................................................................................................................417 POWER STEERING MOTOR AND PUMP.........................................................................................................418 DESCRIPTION.......................................................................................................................418 REMOVAL AND DISASSEMBLY...........................................................................................................418 ASSEMBLY AND INSTALLATION.........................................................................................................419 REPAIRS, POWER STEERING PUMP......................................................................................................419 Seal Replacement..............................................................................................................420 HYDRAULIC STEERING MOTOR..............................................................................................................421 DESCRIPTION.......................................................................................................................421 REPAIRS, HYDRAULIC STEERING MOTOR.................................................................................................422 Removal.......................................................................................................................422 Disassembly...................................................................................................................422 Cleaning And Inspection.......................................................................................................422 Assembly......................................................................................................................422 Installation, Hydraulic Steering Motor........................................................................................424 STEERING TRUNNION ASSEMBLY............................................................................................................425 TRUNNION AND WHEEL ASSEMBLY.......................................................................................................425 Removal.......................................................................................................................425 Installation..................................................................................................................425 Removal of the Wheel Assembly.................................................................................................427 Installation of the Wheel Assembly............................................................................................427 CHECKS AND ADJUSTMENTS................................................................................................................427 Air In The Steering System........................................................................................................427 Steering Chain Tension........................................................................................................427 Check The Operation...........................................................................................................427 Steering Pressure.............................................................................................................427 Control Switches for Traction Motors..........................................................................................428 TROUBLESHOOTING.......................................................................................................................429 INTRODUCTION..........................................................................................................................430 GENERAL...........................................................................................................................430 DESCRIPTION.......................................................................................................................430 REPAIRS...............................................................................................................................430 REMOVAL...........................................................................................................................430 DISASSEMBLY.......................................................................................................................430 CLEANING..........................................................................................................................430 ASSEMBLY..........................................................................................................................430 Tilt Cylinders with O-Rings or Single Lip Seals...............................................................................430 Tilt Cylinders for the XM and XMS Models......................................................................................431 Tilt Cylinders for H700 800A and Early Model H700 920B........................................................................433 INSTALLATION......................................................................................................................433 Tilt Cylinders Using Chevron Packing..........................................................................................434 CHECKS AND ADJUSTMENTS................................................................................................................436 CHECK THE TILT CYLINDERS FOR LEAKS................................................................................................436 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...........................................................................436 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS..............................................................................437 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS.............................................................................438 TROUBLESHOOTING.......................................................................................................................440 INTRODUCTION..........................................................................................................................441 General...........................................................................................................................441 Description.......................................................................................................................441 REPAIRS...............................................................................................................................444 Removal...........................................................................................................................444 Disassembly.......................................................................................................................445 Assembly..........................................................................................................................445 Installation......................................................................................................................446 WHEELS AND TIRES......................................................................................................................447 Description.......................................................................................................................447 TROUBLESHOOTING.......................................................................................................................449 INTRODUCTION..........................................................................................................................450 GENERAL...........................................................................................................................450 MAST WELDMENTS....................................................................................................................450 CARRIAGE..........................................................................................................................450 MAST MOUNTS.......................................................................................................................451 VISTA® TWO-STAGE MAST.................................................................................................................452 DESCRIPTION AND OPERATION.........................................................................................................452 VISTA® FREE-LIFT MAST.................................................................................................................454 DESCRIPTION.......................................................................................................................454 OPERATION.........................................................................................................................454 VISTA® THREE-STAGE MAST...............................................................................................................456 DESCRIPTION.......................................................................................................................456 OPERATION.........................................................................................................................456 VISTA® FOUR-STAGE MAST................................................................................................................457 DESCRIPTION.......................................................................................................................457 OPERATION.........................................................................................................................458 VISTA MAST, REPAIR....................................................................................................................460 GENERAL...........................................................................................................................460 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................................460 FORKS.............................................................................................................................461 Forks, Removal And Installation...............................................................................................461 CARRIAGE..........................................................................................................................462 Removal.......................................................................................................................462 Installation..................................................................................................................463 MASTS.............................................................................................................................463 Removal.......................................................................................................................463 Disassembly...................................................................................................................464 Cleaning and Inspection.......................................................................................................469 Assembly......................................................................................................................469 Installation..................................................................................................................473 SIDE-SHIFT CARRIAGE (EARLIER DESIGN)..............................................................................................474 Removal.......................................................................................................................474 Repairs.......................................................................................................................474 Installation..................................................................................................................474 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN).......................................................................................475 Removal.......................................................................................................................475 Repairs.......................................................................................................................475 Installation..................................................................................................................476 CHECKS AND ADJUSTMENTS................................................................................................................477 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.......................................................................................477 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................................................478 LIFT CHAIN ADJUSTMENTS............................................................................................................479 MAST ADJUSTMENTS..................................................................................................................479 CARRIAGE ADJUSTMENT...............................................................................................................481 HEADER HOSE ARRANGEMENTS..........................................................................................................481 Two-Stage Header Hose.........................................................................................................482 Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts.................................................................482 TROUBLESHOOTING.......................................................................................................................487
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]
