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Hyster Forklift J30 40XMT service manual – PDF DOWNLOAD
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Description
Hyster Forklift J30 40XMT service manual
File Details:
Hyster Forklift J30 40XMT service manual
Language : English
Pages : 421
Size : 11.9 MB
Downloadable : Yes
Format : PDF
HYSTER FORKLIFT J30 40XMT SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster Forklift J30 40XMT service manual
- GENERAL This section has the description and repairs for the brake system. These parts include the park brake, service brake and master cylinder, the disassembly and assembly of the service brakes and the park brakes. The electrically released park brake is also described in this section. Checks and Adjustments are described at the end of this section. DESCRIPTION The J30XMT, J35XMT, J40XMT J1.60XMT, J1.80XMT and J2.00XMT lift trucks feature dual hydraulically operated service disc brakes and mechanically operated park disc brakes. Both brake systems operate independently of each other although they both use a single disc mounted on the bevel gear shaft of the transaxle for braking.
- The location provides a mechanical advantage for effective braking. The service brake master cylinder and separate reservoir are sealed. The reservoir has a level sensor connected to a warning light in the instrument panel, which displays when the brake fluid is low. The service brake is actuated by the large pedal located in the operator’s compartment. The pedal can be operated with either the left or right foot. The park brake is set by a pedal operated by the operator’s left foot. The park brake is released by operating the release lever located on the left side of the instrument panel. Both a warning buzzer and indicator light are used to remind the operator to set and release the park brake.
- The lift truck may also be furnished with an optional electrically operated park brake. When furnished, the park brake applies when the operator leaves the seat of the lift truck. The park brake mechanism is attached to the park brake linkage at the front of the lift truck and replaces the standard park brake linkage.
Table of Contents:
Hyster Forklift J30 40XMT service manual
INTRODUCTION......................................................................................................... 1 GENERAL.......................................................................................................... 1 DESCRIPTION...................................................................................................... 1 REPAIRS.............................................................................................................. 1 SERVICE BRAKE PADS............................................................................................... 1 Removal...................................................................................................... 1 Installation................................................................................................. 1 SERVICE BRAKE CALIPER............................................................................................ 2 Removal...................................................................................................... 2 Installation................................................................................................. 3 Disassembly.................................................................................................. 3 Assembly..................................................................................................... 4 PARK BRAKE CALIPER............................................................................................... 4 Removal...................................................................................................... 4 Installation................................................................................................. 4 Disassembly.................................................................................................. 4 Assembly..................................................................................................... 5 MASTER CYLINDER.................................................................................................. 5 Removal...................................................................................................... 5 Installation................................................................................................. 6 Disassembly.................................................................................................. 6 Assembly..................................................................................................... 6 FOOT OPERATED PARK BRAKE LEVER ASSEMBLY.......................................................................... 7 Removal...................................................................................................... 7 Installation................................................................................................. 7 ELECTRICALLY RELEASED PARK BRAKE................................................................................. 9 Mechanical Operation......................................................................................... 9 Removal...................................................................................................... 9 Installation................................................................................................. 10 ELECTRICALLY RELEASED PARK BRAKE-ELECTRICAL COMPONENTS........................................................... 12 Control Box-Removal.......................................................................................... 12 Control Box-Installation..................................................................................... 14 Terminal Block-removal....................................................................................... 14 Terminal Block-Installation.................................................................................. 14 CHECKS AND ADJUSTMENTS............................................................................................... 14 PARK BRAKE ADJUSTMENT............................................................................................ 14 SERVICE BRAKE ADJUSTMENT......................................................................................... 15 REMOVE AIR FROM BRAKE SYSTEM..................................................................................... 15 TROUBLESHOOTING...................................................................................................... 16 INTRODUCTION......................................................................................................... 25 ELECTRIC MOTOR MAINTENANCE, GENERAL.............................................................................. 25 BRUSH AND COMMUNICATOR INSPECTION................................................................................ 25 Hydraulic Pump Motor And Traction Motor...................................................................... 25 Steering Pump Motor.......................................................................................... 27 BRUSH WEAR REPLACEMENT GUIDE......................................................................................... 27 Commutator Problems.............................................................................................. 29 BRUSH REPLACEMENTS............................................................................................... 31 DISASSEMBLY OF MOTORS............................................................................................ 33 Traction Motor And Hydraulic Pump Motor...................................................................... 33 Steering Pump Motor.......................................................................................... 39 ASSEMBLY OF MOTORS............................................................................................... 41 Traction Motor And Hydraulic Pump Motor ..................................................................... 41 Steering Pump Motor.......................................................................................... 41 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS................................................................... 41 TESTS FOR A DAMAGED FIELD AND ARMATURE........................................................................... 42 Test For An Open Circuit In The Armature..................................................................... 42 Test For A Short-Circuit In One Armature Winding............................................................. 42 Test For A Short-Circuit To Armature Shaft................................................................... 43 Test For An Open Circuit In A Field Coil..................................................................... 43 Test For A Short-Circuit In A Field Coil..................................................................... 43 Test For A Short-Circuit Between The Field And The Motor Case................................................ 44 Brush Holder Test............................................................................................ 44 TROUBLESHOOTING...................................................................................................... 44 FIGURE 1. WIRING SCHEMATIC......................................................................................... 47 FIGURE 2. WIRING DIAGRAM........................................................................................... 51 FIGURE 3. WIRING SCHEMATIC WITH SCR HYDRAULICS..................................................................... 55 FIGURE 4. WIRING DIAGRAM WITH SCR HYDRAULICS....................................................................... 59 FIGURE 5. OPTIONAL WIRING.......................................................................................... 62 FIGURE 6. CABLE DETAILS............................................................................................ 63 FIGURE 7. ARRANGEMENT ELECTRICAL CONTROL WITH SCR HYDRAULICS....................................................... 64 FIGURE 8. ARRANGEMENT ELECTRICAL CONTROL WITH CONTACTOR HYDRAULICS................................................. 65 FIGURE 9. ARRANGEMENT, HYDRAULIC SYSTEM............................................................................ 66 FIGURE 10. HYDRAULIC SCHEMATIC....................................................................................... 67 WIRING SCHEMATIC WITH SCR CONTROLLED LIFT PUMP....................................................................... 70 WIRING DIAGRAM WITH SCR CONTROLLED LIFT PUMP......................................................................... 74 OPTIONAL WIRING WITH SCR CONTROLLED LIFT PUMP........................................................................ 75 WIRING SCHEMATIC WITH CONTACTOR CONTROLLED LIFT PUMP................................................................. 78 WIRING DIAGRAM WITH CONTACTOR CONTROLLED LIFT PUMP................................................................... 82 OPTIONAL WIRING WITH CONTACTOR CONTROLLED LIFT PUMP.................................................................. 83 OPTIONAL MAIN LIGHTS WIRING.......................................................................................... 85 CABLE DETAILS........................................................................................................ 88 ELECTRICAL ARRANGEMENT WITH SCR CONTROLLED LIFT PUMP................................................................. 89 ELECTRICAL ARRANGEMENT WITH CONTACTOR CONTROLLED LIFT PUMP........................................................... 90 HYDRAULIC SYSTEM ARRANGEMENT......................................................................................... 91 HYDRAULIC SCHEMATIC.................................................................................................. 92 INTRODUCTION......................................................................................................... 93 GENERAL.......................................................................................................... 93 DESCRIPTION.......................................................................................................... 93 INSTRUMENT PANELS................................................................................................ 93 Standard Display............................................................................................. 94 Preminum Display ............................................................................................ 94 PRINTED CIRCUIT BOARDS........................................................................................... 96 Steering Angle Control Board................................................................................. 97 Lift Pump Control Board...................................................................................... 97 REPLACEMENT.......................................................................................................... 97 INSTRUMENT PANEL COMPONENTS...................................................................................... 98 Instrument Panel Assembly.................................................................................... 98 Key Switch...................................................................................................100 Battery Indicators...........................................................................................100 Hourmeter (Standard Panel Only)..............................................................................100 Indicator Lights.............................................................................................100 PRINTED CIRCUIT BOARDS...........................................................................................100 Steering Angle Control Board.................................................................................100 Lift Pump Control Board......................................................................................101 OTHER CONTROL COMPONENTS.........................................................................................101 Accelerator Switch Assembly..................................................................................101 Stop Light Switch............................................................................................102 Seat Switch..................................................................................................102 Parking Brake Switch.........................................................................................103 Direction Switches (Monotrol Pedal)..........................................................................104 Direction Control Switches (Steering Column).................................................................104 Hydraulic Cut Off Switch.....................................................................................105 Brake Fluid Switch...........................................................................................106 Motor Temperature Switches...................................................................................106 Rocker Switches for Lights...................................................................................106 Lights and Reverse Alarm.....................................................................................106 Horn and Horn Button.........................................................................................109 CHECKS AND ADJUSTMENTS...............................................................................................111 CONTROL AND POWER FUSES..........................................................................................111 CHECK ACCELERATOR SWITCH ASSEMBLY................................................................................113 ADJUSTING STOP LIGHT SWITCH......................................................................................113 CHECK SEAT SWITCH................................................................................................113 ADJUSTING PARKING BRAKE SWITCH...................................................................................113 DIRECTION SWITCHES (MONOTROL PEDAL)..............................................................................113 DIRECTION SWITCHES (STEERING COLUMN).............................................................................113 HYDRAULIC CUT OFF SWITCH.........................................................................................114 PRINTED CIRCUIT BOARDS...........................................................................................114 Steering Angle Control Board.....................................................................................115 Lift Pump Control Board..........................................................................................115 Bypassing the Lift Pump Control Board............................................................................119 INTRODUCTION.........................................................................................................122 General..........................................................................................................122 DESCRIPTION..........................................................................................................122 Diagnostic Control Card..........................................................................................122 Status Codes.................................................................................................124 Hand Set.........................................................................................................124 Instrument Panel Display.........................................................................................125 Hourmeter Functions..........................................................................................125 Battery Indicator Functions..................................................................................125 Control Card Connections.........................................................................................126 CHECKS AND ADJUSTMENTS...............................................................................................132 General..........................................................................................................132 Function Codes...............................................................................................132 Connecting The Control Card For Bench Checks And Adjustments.................................................133 Connecting The Hand Set To A Control Card Installed In A Lift Truck..........................................134 Checking And Adjusting Function Settings.........................................................................134 General......................................................................................................134 How To Connect And Check Hand Set ...........................................................................134 How To Check And Adjust Functions............................................................................134 Function Descriptions........................................................................................135 Traction Control Cards (EV-100/200 LXT-LX)...................................................................135 Pump Control Card (EV-100/200 LXP)...........................................................................139 Dual Motor Traction Control Card (EV-100 LXM)................................................................140 Function Tables..................................................................................................143 REPAIRS..............................................................................................................156 General..........................................................................................................156 Control Card Plugs...............................................................................................156 TROUBLESHOOTING......................................................................................................157 General..........................................................................................................157 INTRODUCTION.........................................................................................................192 GENERAL..........................................................................................................192 DESCRIPTION......................................................................................................192 REPAIRS..............................................................................................................193 OVERHEAD GUARD...................................................................................................193 Removal......................................................................................................193 Installation.................................................................................................194 HOOD AND SEAT ASSEMBLY...........................................................................................194 Removal......................................................................................................195 Installation.................................................................................................196 COUNTERWEIGHT....................................................................................................196 Removal......................................................................................................196 Installation.................................................................................................197 HYDRAULIC TANK...................................................................................................197 Inspection...................................................................................................197 Repairs, Small Leaks.........................................................................................197 Repairs. Large Leaks.........................................................................................197 Cleaning.....................................................................................................197 Steam Method Of Cleaning.....................................................................................198 Chemical Solution Method of Cleaning.........................................................................198 Additional Preparations For Repair...........................................................................198 SAFETY LABELS....................................................................................................199 BATTERY SIZE SPECIFICATIONS..........................................................................................202 INTRODUCTION.........................................................................................................204 GENERAL..........................................................................................................204 LEAD-ACID BATTERIES..............................................................................................204 SPECIFIC GRAVITY.................................................................................................205 CHEMICAL REACTION IN A CELL......................................................................................205 ELECTRICAL TERMS.................................................................................................206 HOW TO SELECT THE BATTERY........................................................................................206 VOLTAGE OF A BATTERY.............................................................................................206 THE BATTERY AS A COUNTERWEIGHT...................................................................................207 BATTERY RATINGS..................................................................................................207 Kilowatt-Hours...............................................................................................208 BATTERY MAINTENANCE..................................................................................................208 SAFETY PROCEDURES................................................................................................208 MAINTENCE RECORDS................................................................................................209 THE NEW BATTERY..................................................................................................209 HOW TO CLEAN THE BATTERY.........................................................................................210 HOW TO ADD WATER.................................................................................................210 THE HYDROMETER...................................................................................................211 BATTERY TEMPERATURE..............................................................................................211 CHARGING THE BATTERY.............................................................................................212 Types Of Battery Charges.....................................................................................213 Methods Of Charging..........................................................................................214 Troubleshooting The Charger..................................................................................214 How to Know When The Battery Is Fully Charged................................................................215 WHERE TO CHARGE THE BATTERIES....................................................................................215 Equipment Needed.............................................................................................215 BATTERY CONNECTORS...............................................................................................216 BATTERY CARE.....................................................................................................216 INTRODUCTION.........................................................................................................218 GENERAL..........................................................................................................218 DESCRIPTION......................................................................................................218 REPAIRS..............................................................................................................222 REMOVAL AND DISASSEMBLY..........................................................................................222 ASSEMBLY AND INSTALLATION........................................................................................222 INTRODUCTION.........................................................................................................225 GENERAL..........................................................................................................225 DESCRIPTION......................................................................................................225 OPERATION........................................................................................................226 Lift Section.................................................................................................226 Tilt Section.................................................................................................227 Relief Valve.................................................................................................227 REPAIRS..............................................................................................................227 MAIN CONTROL VALVE...............................................................................................227 Removal......................................................................................................227 Installation.................................................................................................228 Disassembly..................................................................................................231 Cleaning And Inspection......................................................................................233 Assembly.....................................................................................................233 CHECKS AND ADJUSTMENTS...............................................................................................234 RELIEF VALVE.....................................................................................................234 VANE SETTINGS....................................................................................................234 MAST TILT ADJUSTMENT.............................................................................................234 TROUBLESHOOTING......................................................................................................235 INTRODUCTION.........................................................................................................238 GENERAL..........................................................................................................238 DESCRIPTION AND OPERATION........................................................................................238 Carriages....................................................................................................238 Mast Mounts..................................................................................................239 TWO-STAGE MAST, LIMITED FREE-LIFT................................................................................240 Description and Operation....................................................................................240 TWO-STAGE MAST, FULL FREE-LIFT...................................................................................242 Description..................................................................................................242 Operation....................................................................................................242 THREE-STAGE, FULL FREE-LIFT MAST.................................................................................244 Description..................................................................................................244 Operation....................................................................................................244 INTRODUCTION ........................................................................................................246 GENERAL .........................................................................................................246 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ........................................................................246 REPAIRS .............................................................................................................247 FORKS ...........................................................................................................247 Removal .....................................................................................................247 Installation ................................................................................................248 CARRIAGES .......................................................................................................248 Removal, Standard Carriage ..................................................................................248 Removal, Side–Shift Carriage ................................................................................249 Repairs .....................................................................................................249 Installation, Standard Carriage .............................................................................249 Installation, Side–Shift Carriage ...........................................................................250 MAST ............................................................................................................251 Removal .....................................................................................................251 Disassembly, Three–Stage FFL Mast ...........................................................................257 Disassembly, Two–Stage LFL And Two–Stage FFL Masts ..........................................................251 Cleaning and Inspection .....................................................................................257 Assembly, Two–Stage LFL And Two–Stage FFL Mast ..............................................................260 Assembly, Three–Stage FFL Mast ..............................................................................261 Installation, Mast ..........................................................................................262 LIFT CYLINDERS ..................................................................................................263 Removal, Main Lift Cylinders ................................................................................263 Removal, Free–Lift Cylinder .................................................................................263 Disassembly, Lift Cylinders .................................................................................263 Assembly, Lift Cylinders ....................................................................................264 Installation, Main Lift Cylinders ...........................................................................265 Installation, Free–Lift Cylinder ............................................................................266 HEADER HOSE ARRANGEMENTS H/S/E/J2.00–3.20XM (H/S/E/J40–65XM) S/E/J2.00–3.00XL (S/E/J40–60XL) ....................267 New Hose Installation, Two–Stage, LFL Mast ..................................................................267 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................267 New Hose Installation, Two–Stage FFL Mast ...................................................................271 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................271 New Hose Installation, Three–Stage FFL Mast .................................................................275 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................280 HEADER HOSE ARRANGEMENTS H/E1.50–1.75XM, H/S2.00XMS (H/S/E25–35XM, H/S/E40XMS) and J1.60–2.00XMT (J30–40XMT) ....282 New Hose Installation, Two–Stage LFL Mast ...................................................................283 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................283 New Hose Installation, Two–Stage FFL Mast ...................................................................286 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................286 New Hose Installation, Three–Stage, FFL Mast ................................................................290 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................295 CHECKS AND ADJUSTMENTS ..............................................................................................296 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ....................................................................296 Check The Lift Cylinders For Leaks .........................................................................296 Check The Tilt Cylinders For Leaks .........................................................................296 ADJUST THE TILT CYLINDERS ......................................................................................296 ADJUST THE LIFT CHAINS .........................................................................................297 ADJUST THE MAST ................................................................................................298 ADJUST THE CARRIAGE ............................................................................................299 TROUBLESHOOTING......................................................................................................300 INTRODUCTION.........................................................................................................301 GENERAL..........................................................................................................301 HOW TO MOVE A DISABLED LIFT TRUCK................................................................................301 HOW TO TOW A LIFT TRUCK..........................................................................................301 HOW TO PUT A LIFT TRUCK ONTO BLOCKS..............................................................................302 How to Raise the Load Wheels.................................................................................302 How to Raise the Steer Wheel.................................................................................303 MAINTENANCE SCHEDULE.................................................................................................303 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY........................................................................305 CHECKS BEFORE OPERATION..........................................................................................305 Hydraulic System.............................................................................................305 Battery......................................................................................................306 Operator Restraint System....................................................................................306 Battery Restraint System.....................................................................................307 Tires and Wheels.............................................................................................307 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................308 Forks........................................................................................................310 Forks, Adjustment............................................................................................310 Forks, Removal...............................................................................................310 Forks, Inspection ...........................................................................................310 Forks, Installation..........................................................................................311 Mast and Lift Chains.........................................................................................311 Lift Chain Adjustments.......................................................................................312 CHECK THE OPERATION..............................................................................................312 Gauges and Horn..............................................................................................312 Control Levers and Pedals....................................................................................313 Service Brakes...............................................................................................313 Parking Brake................................................................................................313 Steering System..............................................................................................313 EVERY 350 HOURS OR TWO MONTHS........................................................................................313 HYDRAULIC TANK BREATHER..........................................................................................313 WHEEL NUT TORQUE.................................................................................................313 STEERING TRUNNION MOUNTING CAPSCREW TORQUE.......................................................................313 TRANSAXLE........................................................................................................314 LIFT SYSTEM OPERATION............................................................................................314 MAST.............................................................................................................315 LIFT CHAINS......................................................................................................316 FORKS............................................................................................................316 SAFETY LABELS....................................................................................................316 BRAKE FLUID......................................................................................................317 OTHER LUBRICATION................................................................................................317 ELECTRICAL INSPECTION............................................................................................317 Contactors...................................................................................................317 Motor Brushes................................................................................................320 Parking Brake................................................................................................321 2000 HOURS OR YEARLY.................................................................................................321 HYDRAULIC SYSTEM.................................................................................................321 Change the Hydraulic Oil Filter..............................................................................321 Check the Hydraulic Oil Strainer.............................................................................321 Change the Hydraulic Oil.....................................................................................321 BRAKES...........................................................................................................322 Adjust the Parking Brake.....................................................................................322 TRANSAXLE........................................................................................................324 EVERY 4000 HOURS.....................................................................................................324 TRANSAXLE (S2 SERIES ONLY).......................................................................................324 GENERAL PROCEDURES...................................................................................................325 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM......................................................................325 LIFT SYSTEM......................................................................................................325 TILT SYSTEM......................................................................................................325 HOW TO CHECK THE PMT CIRCUIT.....................................................................................325 HOW TO CHARGE THE BATTERY........................................................................................326 HOW TO CHANGE THE BATTERY........................................................................................327 WHEELS AND TIRES.....................................................................................................328 GENERAL..........................................................................................................328 HOW TO CHANGE THE TIRES..........................................................................................328 STEER AND DRIVE WHEELS...........................................................................................329 PNEUMATIC TIRES..................................................................................................329 Remove the Wheel from the lift truck.........................................................................329 Remove the Tire from the Wheel...............................................................................330 Install The Tire On The Wheel................................................................................330 Add Air to the Tires.........................................................................................331 PNEUMATIC SHAPED SOLID TIRES.....................................................................................332 Remove the Wheel from the lift truck.........................................................................332 Remove the Tire from the Wheel...............................................................................332 Install the Tire on the Wheel................................................................................333 SOLID TIRES......................................................................................................334 Remove the One Piece Wheel and Tire..........................................................................334 Install the Tire on the One Piece Wheel......................................................................334 INSTALL THE WHEEL AND TIRE.......................................................................................335 BATTERY SIZE SPECIFICATIONS......................................................................................336 INTRODUCTION.........................................................................................................338 NOMENCLATURE, THREADS............................................................................................338 STRENGTH IDENTIFICATION..........................................................................................339 TABLE 1. BOLTS AND SCREWS............................................................................................339 TABLE 2. STUDS AND NUTS..............................................................................................340 TABLE 3. TORQUE NUTS.................................................................................................341 TABLE 4. TORQUE NUTS WITH NYLON INSERT...............................................................................342 TABLE 5. TORQUE VALUES FOR INCH FASTENERS............................................................................343 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..........................................................................344 INTRODUCTION.........................................................................................................347 GENERAL..........................................................................................................347 DESCRIPTION......................................................................................................347 OPERATION........................................................................................................347 REPAIRS..............................................................................................................348 STEERING WHEEL AND COLUMN ASSEMBLY...............................................................................348 Removal of the Assembly Components...........................................................................352 Disassembly of the Steering Control Unit.....................................................................353 Cleaning of the Steering Control Unit........................................................................353 Assembly of the Steering Control Unit........................................................................353 Installation of the Steering Control Unit....................................................................353 Installation of the Assembly Components......................................................................353 CHECKS AND ADJUSTMENTS...............................................................................................361 REMOVE AIR FROM THE SYSTEM.......................................................................................361 TROUBLESHOOTING......................................................................................................361 INTRODUCTION.........................................................................................................363 General..........................................................................................................363 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................................363 DESCRIPTION......................................................................................................363 Removal......................................................................................................363 POWER STEERING PUMP AND MOTOR........................................................................................367 DESCRIPTION......................................................................................................367 Removal......................................................................................................367 Installation.................................................................................................368 REPAIRS..........................................................................................................368 Disassembly..................................................................................................368 Assembly.....................................................................................................369 STEERING TRUNNION ASSEMBLY...........................................................................................370 STEER AXLE.......................................................................................................370 WHEEL ASSEMBLY...................................................................................................370 Removal......................................................................................................370 Installation.................................................................................................370 WHEEL HUB........................................................................................................370 Removal......................................................................................................370 Installation.................................................................................................372 STEER AXLE ASSEMBLY..............................................................................................372 Removal......................................................................................................372 Installation.................................................................................................373 POWER STEERING CYLINDER..........................................................................................374 Removal......................................................................................................374 Installation.................................................................................................374 Disassembly..................................................................................................374 Assembly.....................................................................................................375 CHECKS AND ADJUSTMENTS...............................................................................................375 Air In The Steering System.......................................................................................375 Check The Operation..........................................................................................375 Steering Pressure............................................................................................375 TROUBLESHOOTING......................................................................................................376 INTRODUCTION.........................................................................................................379 GENERAL..........................................................................................................379 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................................379 DESCRIPTION......................................................................................................379 Removal......................................................................................................379 POWER STEERING PUMP AND MOTOR........................................................................................383 DESCRIPTION......................................................................................................383 Removal......................................................................................................383 Installation.................................................................................................384 REPAIRS..........................................................................................................384 Disassembly..................................................................................................384 Assembly.....................................................................................................385 STEERING TRUNNION ASSEMBLY...........................................................................................386 STEER AXLE.......................................................................................................386 WHEEL ASSEMBLY...................................................................................................386 Removal......................................................................................................386 Installation.................................................................................................386 WHEEL HUB........................................................................................................386 Removal......................................................................................................386 Installation.................................................................................................388 STEER AXLE ASSEMBLY..............................................................................................388 Removal......................................................................................................388 Installation.................................................................................................389 POWER STEERING CYLINDER..........................................................................................390 Removal......................................................................................................390 Installation.................................................................................................390 Disassembly..................................................................................................390 Assembly.....................................................................................................391 CHECKS AND ADJUSTMENTS...............................................................................................391 AIR IN THE STEERING SYSTEM.......................................................................................391 Check the Operation..........................................................................................391 Steering Pressure............................................................................................391 TROUBLESHOOTING......................................................................................................392 INTRODUCTION.........................................................................................................395 GENERAL..........................................................................................................395 DESCRIPTION......................................................................................................395 REPAIRS..............................................................................................................395 REMOVAL..........................................................................................................395 DISASSEMBLY......................................................................................................395 CLEANING.........................................................................................................395 ASSEMBLY.........................................................................................................395 Tilt Cylinders with O-Rings or Single Lip Seals..............................................................395 Tilt Cylinders for the XM and XMS Models.....................................................................396 Tilt Cylinders for H700 800A and Early Model H700 920B.......................................................398 INSTALLATION.....................................................................................................398 Tilt Cylinders Using Chevron Packing.........................................................................399 CHECKS AND ADJUSTMENTS...............................................................................................401 CHECK THE TILT CYLINDERS FOR LEAKS...............................................................................401 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..........................................................401 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS.............................................................402 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS............................................................403 TROUBLESHOOTING......................................................................................................405 INTRODUCTION.........................................................................................................406 GENERAL..........................................................................................................406 LUBRICATION......................................................................................................406 REPAIRS..............................................................................................................407 REMOVAL..........................................................................................................407 INSPECTION.......................................................................................................408 INSTALLATION.....................................................................................................408 S2 SERIES TRANSAXLE..................................................................................................409 DISASSEMBLY......................................................................................................409 ASSEMBLY.........................................................................................................410 General......................................................................................................410 Ring Gear Installation.......................................................................................410 Intermediate Shaft Installation..............................................................................410 Axle Shaft Installation......................................................................................411 Pinion Gear Installation.....................................................................................411 Final Assembly...............................................................................................415 S1 SERIES TRANSAXLE..................................................................................................417 DISASSEMBLY......................................................................................................417 ASSEMBLY.........................................................................................................417 TROUBLESHOOTING......................................................................................................421
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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