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Hyster Forklift N30XMH service manual – PDF DOWNLOAD
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Hyster Forklift N30XMH service manual
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Description
Hyster Forklift N30XMH service manual
File Details:
Hyster Forklift N30XMH service manual
Language : English
Pages : 555
Size : 15.5 MB
Downloadable : Yes
Format : PDF
HYSTER FORKLIFT N30XMH SERVICE MANUAL – PDF DOWNLOAD:
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Description:
Hyster Forklift N30XMH service manual
- GENERAL This section has the description, disassembly, assembly, checks and adjustments for the attachment. Troubleshooting and specification tables are at the end of the section. DESCRIPTION (See FIGURE 1., FIGURE 2. and FIGURE 3. ) The mast lifts and lowers the attachment. The N30XMH attachment has an optional side shift carriage. Load rollers on this carriage fit into the channels of the inner mast. A traverse frame mounts on the side shift carriage with rollers
- . A side shift cylinder connects the side shift carriage and the traverse frame. Actuation of the cylinder rod moves the entire attachment to the right or left of the lift truck. This movement is the optional ”side shift” function. On trucks without side shift, load rollers on the traverse frame fit into the channels of the inner mast. A boom is fastened to the traverse frame by rollers. The boom is moved left and right by a traverse cylinder and chain arrangement.
- One end of each chain is connected to the traverse frame. The other end of each chain is connected to the boom. As the shell of the traverse cylinder moves to the left or right, it pulls the boom in the same direction. This movement is the ”traverse” function. A rotary actuator is attached to the end of the boom. A fork carriage is fastened to the rotary actuator. The rotary actuator moves the fork carriage and forks in a 180 degree arc for left and right hand load handling. Movement of the forks in an arc is the ”rotate” function
- . Movement of all of these parts are controlled by the hydraulic control levers beside the seat. Information on the hydraulic valves for the attachment are in the section for the HYDRAULIC SYSTEM, 1900 SRM 559.
Table of Contents:
Hyster Forklift N30XMH service manual
INTRODUCTION................................................................................................................................ 1 GENERAL................................................................................................................................. 1 DESCRIPTION............................................................................................................................. 1 REPAIR...................................................................................................................................... 2 ATTACHMENT REMOVAL...................................................................................................................... 2 DISASSEMBLY............................................................................................................................. 3 Side Shift Cylinder And Carriage.................................................................................................... 3 Traverse Cylinder................................................................................................................... 4 Boom................................................................................................................................ 4 Rotary Actuator And Fork Carriage................................................................................................... 5 ASSEMBLY................................................................................................................................ 5 Side Shift / Traverse Installation.................................................................................................. 5 Boom................................................................................................................................ 6 Rotary Actuator And Fork Carriage................................................................................................... 7 CHECKS AND ADJUSTMENTS...................................................................................................................... 7 THRUST ROLLERS ON THE SIDE SHIFT CARRIAGE............................................................................................... 7 THRUST ROLLERS ON THE BOOM.............................................................................................................. 7 LOAD ROLLERS ON THE BOOM................................................................................................................ 7 TRAVERSE CHAIN ADJUSTMENT............................................................................................................... 8 TROUBLESHOOTING............................................................................................................................. 8 SPECIFICATIONS.......................................................................................................................... 9 TABLE 1. TORQUE SPECIFICATIONS FOR THE ATTACHMENT....................................................................................... 9 TABLE 2. CLEARANCES..................................................................................................................... 9 INTRODUCTION................................................................................................................................ 10 GENERAL................................................................................................................................. 10 DESCRIPTION AND OPERATION............................................................................................................... 10 Service Brakes...................................................................................................................... 10 Master Cylinder..................................................................................................................... 10 Parking Brake....................................................................................................................... 12 SERVICE BRAKES.......................................................................................................................... 12 Removal And Disassembly............................................................................................................. 12 Cleaning............................................................................................................................ 14 Inspection.......................................................................................................................... 15 Assembly And Installation........................................................................................................... 15 Adjustments......................................................................................................................... 17 PARKING BRAKE........................................................................................................................... 17 Removal And Disassembly............................................................................................................. 17 Assembly And Installation........................................................................................................... 18 Adjust The Parking Brake............................................................................................................ 18 MASTER CYLINDER......................................................................................................................... 21 Removal............................................................................................................................. 21 Cleaning And Inspection............................................................................................................. 21 Repair.............................................................................................................................. 21 Installation........................................................................................................................ 21 SEAT BRAKE ASSEMBLY..................................................................................................................... 24 CHECKS AND ADJUSTMENTS...................................................................................................................... 25 ADJUST THE SERVICE BRAKES............................................................................................................... 25 ADJUST THE BRAKE PEDAL.................................................................................................................. 25 ADJUST THE MASTER CYLINDER.............................................................................................................. 25 REMOVE THE AIR FROM THE BRAKE SYSTEM.................................................................................................... 25 TEST THE "PARKING BRAKE NOT APPLIED" WARNING............................................................................................ 25 TROUBLESHOOTING............................................................................................................................. 26 TORQUE SPECIFICATIONS....................................................................................................................... 28 COUNTERWEIGHTS.............................................................................................................................. 31 HYDRAULIC SYSTEM............................................................................................................................ 31 WHEELS AND TIRES ........................................................................................................................... 32 BATTERY SPECIFICATIONS - E2.00-3.20XM (E45-65XM, E45-XM2, N30XMH, N30XMH2).................................................................. 32 BATTERY SPECIFICATIONS - J2.00-3.20XM (J40-65XM, J40-65XM2)................................................................................. 33 CAPACITIES.................................................................................................................................. 33 MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS................................................................................................. 33 E45-65XM MAST SPEEDS (36 or 48 Volt) Americas............................................................................................... 34 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 34 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 35 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 36 E40-65XM, E40-65XM2, N30XMH2 MAST SPEEDS (36 or 48 Volt) (3/99) Americas.................................................................... 37 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*................................................................................................ 37 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*................................................................................................ 38 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 39 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 39 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 40 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 41 E2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 42 CONTACTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*.................................................................................. 42 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................................ 43 E2.00-3.20XM, E2.00-3.20XM2, MAST SPEEDS (72 or 80 Volt) (3/99) Europe...................................................................... 44 190 mm MOTOR & LARGE LIFT PUMP*......................................................................................................... 44 190 mm MOTOR & SMALL LIFT PUMP*......................................................................................................... 45 203 or 190 mm LONG STACK MOTOR & SMALL LIFT PUMP*....................................................................................... 46 J40-65XM MAST SPEEDS (36 or 48 Volt) Americas............................................................................................... 47 CONTACTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*.................................................................................. 47 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 48 CONTACTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*.................................................................................. 49 J40-65XM, J40-65XM2, MAST SPEEDS (36 or 48 Volt) (3/99) Americas............................................................................ 50 190 mm (7.5 in) MOTOR & LARGE LIFT PUMP*................................................................................................ 50 190 mm (7.5 in) MOTOR & SMALL LIFT PUMP*................................................................................................ 51 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) Europe............................................................................................. 52 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................ 52 SCR CONTROLLED STANDARD MOTOR & LARGE LIFT PUMP*........................................................................................ 53 CONT. OR TRANSISTOR CONTROLLED STANDARD MOTOR & SMALL LIFT PUMP*........................................................................ 54 CONT. OR TRANSISTOR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................ 55 SCR CONTROLLED OPTIONAL MOTOR & LARGE LIFT PUMP*........................................................................................ 56 J2.00-3.20XM MAST SPEEDS (72 or 80 Volt) (3/99) Europe...................................................................................... 57 190 mm MOTOR & LARGE LIFT PUMP*......................................................................................................... 57 190 mm MOTOR & SMALL LIFT PUMP*......................................................................................................... 58 203 or 190 mm LONG STACK MOTOR & LARGE LIFT PUMP*....................................................................................... 59 TORQUE SPECIFICATIONS....................................................................................................................... 60 REFERENCE TABLE............................................................................................................................. 63 INTRODUCTION................................................................................................................................ 64 ELECTRIC MOTOR MAINTENANCE, GENERAL..................................................................................................... 64 BRUSH AND COMMUNICATOR INSPECTION....................................................................................................... 64 Hydraulic Pump Motor And Traction Motor............................................................................................. 64 Steering Pump Motor................................................................................................................. 66 BRUSH WEAR REPLACEMENT GUIDE................................................................................................................ 66 Commutator Problems..................................................................................................................... 68 BRUSH REPLACEMENTS...................................................................................................................... 70 DISASSEMBLY OF MOTORS................................................................................................................... 72 Traction Motor And Hydraulic Pump Motor............................................................................................. 72 Steering Pump Motor................................................................................................................. 78 ASSEMBLY OF MOTORS...................................................................................................................... 80 Traction Motor And Hydraulic Pump Motor ............................................................................................ 80 Steering Pump Motor................................................................................................................. 80 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS.......................................................................................... 80 TESTS FOR A DAMAGED FIELD AND ARMATURE.................................................................................................. 81 Test For An Open Circuit In The Armature............................................................................................ 81 Test For A Short-Circuit In One Armature Winding.................................................................................... 81 Test For A Short-Circuit To Armature Shaft.......................................................................................... 82 Test For An Open Circuit In A Field Coil............................................................................................ 82 Test For A Short-Circuit In A Field Coil............................................................................................ 82 Test For A Short-Circuit Between The Field And The Motor Case....................................................................... 83 Brush Holder Test................................................................................................................... 83 TROUBLESHOOTING............................................................................................................................. 83 FIGURE 1. SCHEMATIC - EV - 100ZX SCR CONTROL FOR TRACTION MOTOR............................................................................. 85 FIGURE 2. SCHEMATIC - EV - 100ZX SCR CONTROL FOR LIFT PUMP MOTOR............................................................................ 86 FIGURE 3. SCHEMATIC - CONTACTOR CONTROL FOR LIFT PUMP MOTOR................................................................................. 87 FIGURE 4. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................ 89 FIGURE 5. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................ 91 FIGURE 6. WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH................................................................................ 93 FIGURE 7. WIRING CONNECTIONS, CONTROLLER PANEL-TOPANEL, E2.00-3.20XM (E45-65XM) AND N30XMH.................................................. 94 FIGURE 8. WIRING CONNECTIONS, CONTROLLER PANEL-TO-PANEL, J2.00-3.20XM (J40-65XM)............................................................ 95 FIGURE 9. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM)........................................................................................... 97 FIGURE 10. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM).......................................................................................... 99 FIGURE 11. WIRING DIAGRAM, J2.00-3.20XM (J40-65XM)..........................................................................................101 FIGURE 12. TRUCK WIRING HARNESSES AND CABLES, E2.00-3.20XM (E45-65XM) AND N30XMH............................................................102 FIGURE 13. TRUCK POWER CABLES, E2.00-3.20XM (E45-65XM) AND N30XMH...........................................................................103 FIGURE 14. EV - 100 ZX SCR TRACTION AND PUMP MOTOR CONTROLLERS, E2.00-3.20XM (E45-65XM) AND N30XMH..........................................104 FIGURE 15. EV - 100 ZX SCR TRACTION MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL, E2.00-3.20XM (E45-65XM)....................................105 FIGURE 16. EV - 100ZX SCR TRACTION MOTOR AND SCR PUMP MOTOR CONTROLLERS, E2.00-3.20XM (E45-65XM) AND N30XMH.................................106 FIGURE 17. EV - 100ZX SCR TRACTION MOTOR CONTROLLER WITH CONTACTOR CONTROL OF PUMP MOTOR, E2.00-3.20XM (E45-65XM)...........................107 FIGURE 18. EV - 100ZX CONTACTOR PANEL, E2.00-3.20XM (E45-65XM) AND N30XMH...................................................................108 FIGURE 19. CHASSIS AND HYDRAULIC LINKAGE, SWITCH WIRING DETAILS, E2.00-3.20XM (E45-65XM) AND N30XMH.........................................109 FIGURE 20. TRUCK WIRING HARNESSES AND CABLES, J2.00-3.20XM (J40-65XM).......................................................................110 FIGURE 21. TRUCK POWER CANLES, J2.00-3.20XM (J40-65XM)......................................................................................111 FIGURE 22. EV - 100 ZX SCR TRACTION AND PUMP MOTOR CONTROLLERS, J2.00-3.20XM (J40-65XM).....................................................112 FIGURE 23. EV - 100 ZX SCR TRACTION MOTOR CONTROLLER AND CONTACTOR PUMP CONTROL, J2.00-3.20XM (J40-65XM)....................................113 FIGURE 24. EV - 100ZX SCR TRACTION MOTOR AND SCR PUMP MOTOR CONTROLLERS, J2.00-3.20XM (J40-65XM)............................................114 FIGURE 25. EV - 100ZX SCR TRACTION MOTOR CONTROLLER WITH CONTACTOR CONTROL OF PUMP MOTOR, J2.00-3.20XM (J40-65XM)...........................115 FIGURE 26. EV - 100ZX CONTACTOR PANEL, J2.00-3.20XM (J40-54XM)..............................................................................116 FIGURE 27. CHASSIS AND HYDRAULIC LINKAGE, SWITCH WIRING DETAILS, J2.00-3.20XM (J40-65XM)....................................................117 FIGURE 28. STEERING COLUMN WIRING DETAIL....................................................................................................118 FIGURE 29. DISPLAY PANELS AND PLUG CONNECTORS...............................................................................................119 FIGURE 30. DETAIL OF BATTEY CONNECTORS WITH +12 VOLT TAP....................................................................................120 FIGURE 31. LIGHTING SCHEMATIC (CHASSIS).....................................................................................................121 FIGURE 32. LIGHTING SCHEMATIC (REAR), E2.00-3.02XM (E45-65XM) AND N30XMH....................................................................122 FIGURE 33. LIGHTING SCHEMATIC (REAR), J2.00-3.02XM (J40-65XM)...............................................................................123 FIGURE 34. LIGHTING WIRING DIAGRAM, E2.00-3.20XM (E45-65XM) AND N30XMH......................................................................125 FIGURE 35. LIGHTING WIRING DIAGRAM, J2.00-3.02XM (J40-65XM).................................................................................127 INTRODUCTION................................................................................................................................128 GENERAL.................................................................................................................................128 DESCRIPTION.............................................................................................................................128 REPAIRS.....................................................................................................................................130 REMOVAL OF THE DRIVE AXLE...............................................................................................................130 Disassembly of the Drive Axle.......................................................................................................131 Disassembly of the Transmission and Differential....................................................................................132 CLEANING................................................................................................................................134 INSPECTION..............................................................................................................................134 ASSEMBLY................................................................................................................................134 Assembly Of The Transmission And Differential.......................................................................................134 Assembly Of The Drive Axle..........................................................................................................140 INSTALLATION OF THE DRIVE AXLE ASSEMBLY.................................................................................................141 TROUBLESHOOTING.............................................................................................................................142 TORQUE SPECIFICATIONS.......................................................................................................................143 ELECTRICAL SYSTEM...........................................................................................................................144 GENERAL.................................................................................................................................144 "LX" SERIES DISPLAY PANEL...............................................................................................................145 Hourmeter Functions.................................................................................................................146 Battery Indicator Function..........................................................................................................146 Status Code Function................................................................................................................147 "ZX" SERIES DISPLAY PANELS..............................................................................................................147 Display Panel.......................................................................................................................147 Basic Display Panels................................................................................................................147 Performance Display.................................................................................................................149 Brush Wear Indicators...............................................................................................................152 SEM DISPLAY PANELS - FEATURES...........................................................................................................152 Description Of Common Features......................................................................................................153 LED SYMBOL INDICATORS...............................................................................................................153 LCD SCREEN..........................................................................................................................153 BATTERY DISCHARGE INDICATOR (BDI)...................................................................................................153 SERVICE REMINDER....................................................................................................................153 STATUS CODES........................................................................................................................153 HOURMETER...........................................................................................................................153 Additional Features Of Premium Display Panel .......................................................................................153 Descriptions Of Additional Features (Available With The Premium Display) ...........................................................154 LCD SCREEN..........................................................................................................................154 OPERATOR PASSWORDS..................................................................................................................154 DAILY CHECK LIST AND SERVICE ITEMS..................................................................................................154 PERFORMANCE MODELS..................................................................................................................154 STATUS CODE LISTS...................................................................................................................154 ADJUSTMENTS OF BDI..................................................................................................................155 SEM DISPLAY PANEL INDICATORS............................................................................................................155 All Indicator Symbols...............................................................................................................155 Hourmeter Indicator Symbol..........................................................................................................156 Wrench Indicator Symbol.............................................................................................................156 Battery Indicator Symbol............................................................................................................156 Battery State-Of-Charge (BDI).......................................................................................................156 Brake Fluid Too Low Symbol..........................................................................................................156 Parking Brake Symbol................................................................................................................156 Fasten Seat Belt Symbol.............................................................................................................156 LCD "Screen" (Standard Display Panel)...............................................................................................156 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM.................................................................................156 Alpha Numeric "Screen"..............................................................................................................156 "Star" Push Button..................................................................................................................157 Push Buttons #1 Through #5..........................................................................................................157 OTHER CONTROL COMPONENTS................................................................................................................157 REPLACEMENT.................................................................................................................................158 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"................................................................................................158 Replace The Display Panel Assembly..................................................................................................158 Replace The Key Switch..............................................................................................................159 Indicator LEDs......................................................................................................................159 Battery Indicators..................................................................................................................159 Digital Display (Performance Display Panel Only) ...................................................................................159 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only)........................................161 Replace Parts Of The Basic Display Panel ...........................................................................................161 Replace Parts Of The Performance Display Panel......................................................................................162 SEM DISPLAY PANEL.......................................................................................................................163 Removal And Replacement.............................................................................................................163 REPLACE MOTOR CONTROLLER (SR or SP).....................................................................................................163 OTHER CONTROL COMPONENTS................................................................................................................163 Start Swtich........................................................................................................................163 Brake Light Switch..................................................................................................................164 Seat Switch.........................................................................................................................165 Adjust The External Seat Switch.....................................................................................................166 Switch For Optional Seat Brake......................................................................................................166 Parking Brake Switch................................................................................................................166 Direction Switches (Monotrol Pedal)................................................................................................167 Direction Control Switches (Steering Column)........................................................................................168 Direction Control Switches, E70-120XL3 (Steering Column)............................................................................169 Brake Fluid Switch..................................................................................................................169 Brush Wear And Over Temperature Sensors.............................................................................................169 Rocker Switches For Lights .........................................................................................................170 Accelerator Position Sensor.........................................................................................................170 On-Demand Steering Components.......................................................................................................172 Lights, Converter, Relay And Reverse Alarm..........................................................................................174 Horn And Horn Buttons...............................................................................................................177 Hydraulic Pump Switches.............................................................................................................178 CHECKS AND ADJUSTMENTS......................................................................................................................178 GENERAL.................................................................................................................................178 CONTROL AND POWER FUSES - "LX" OR "ZX"..................................................................................................178 CONTROL AND POWER FUSES - SEM...........................................................................................................181 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"............................................................................184 THERMAL SENSORS - SEM...................................................................................................................184 ADJUST THE START SWITCH.................................................................................................................184 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3...................................................................185 Direction Switches (MONOTROL).......................................................................................................187 ADJUST THE BRAKE LIGHT SWITCH.......................................................................................................187 CHECK SEAT SWITCH...................................................................................................................187 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE...........................................................................................187 ADJUST THE PARKING BRAKE SWITCH.....................................................................................................188 DIRECTIONAL SWITCHES................................................................................................................188 DIRECTIONAL SWITCHES (STEERING COLUMN)..............................................................................................188 HYDRAULIC PUMP SWITCHES.............................................................................................................188 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT......................................................................................188 ADJUST THE ACCELERATOR POSITION SENSOR..............................................................................................189 EV-100ZXE SCR MOTOR CONTROLLER, Description, Adjustments, Troubleshooting, Repairs, and Theory..............................................191 GENERAL.................................................................................................................................191 Model Number Data For EV-100ZX Controller...........................................................................................192 REGISTER PARAMETERS.....................................................................................................................201 General.............................................................................................................................201 Function Members....................................................................................................................201 CONTROL CARD, CHECKS AND ADJUSTMENTS....................................................................................................201 HAND SET................................................................................................................................202 How To Check And Adjust The Registers...............................................................................................202 How To Scroll Through The Fault Codes And Clear Them................................................................................202 Checks And Adjustments On The Work Bench............................................................................................203 When The Hand Set Is Connected To A Control Card Installed In A Lift Truck..........................................................204 FUNCTION NUMBER DESCRIPTIONS............................................................................................................205 TRACTION CONTROL CARDS (LABEL LETTERS - ZH AND ZY)......................................................................................206 PUMP CONTROL CARD (LABEL LETTER ZP).....................................................................................................212 REGISTER PARAMETERS.....................................................................................................................216 TROUBLESHOOTING.........................................................................................................................216 Status Codes........................................................................................................................217 REGISTER MAPS...........................................................................................................................217 STATUS CODE CHARTS..........................................................................................................................226 REPAIRS.....................................................................................................................................258 FUSES...................................................................................................................................259 CHECK AN SCR............................................................................................................................259 THE SCR ASSEMBLY........................................................................................................................260 THERMAL PROTECTOR.......................................................................................................................260 REPLACE THE SCR 1 ASSEMBLY..............................................................................................................260 THE "OFF" CIRCUIT FOR SCR 1.............................................................................................................260 Check The Reactor Assembly..........................................................................................................260 Check Suppressors For SCR 2 And SCR 5...............................................................................................261 Check SCR 2 And SCR 5...............................................................................................................261 Replace SCR 2 And SCR 5.............................................................................................................261 Check Capacitor C1..................................................................................................................261 DIODES D3 AND D4........................................................................................................................261 Check The Diodes D3 And D4..........................................................................................................262 Replacement, Diodes D3 And D4.......................................................................................................262 MOTOR CURRENT SENSOR....................................................................................................................262 CONTACTORS..............................................................................................................................262 Contactor Repair....................................................................................................................263 CONTROL CARD............................................................................................................................264 CONTROL CARD PLUGS......................................................................................................................265 Brush Wear Indicators...............................................................................................................266 THEORY OF OPERATION.........................................................................................................................267 ELECTRONIC SPEED CONTROLS...............................................................................................................267 The Silicon Controlled Rectifier (SCR)..............................................................................................267 A Motor Circuit That Operates With Pulses...........................................................................................267 Traction Circuit....................................................................................................................269 Hydraulic Pump Motor................................................................................................................269 The SCR 1 "OFF" Circuit.............................................................................................................270 INDUCTION CURRENT FROM THE MOTOR........................................................................................................272 CONTROL CARDS...........................................................................................................................272 Pulse Monitor Trip (PMT) (Traction Circuit Only)....................................................................................272 SRO Circuit (Traction Circuit Only).................................................................................................273 SEQUENCE OF OPERATION...................................................................................................................274 Control Card Adjustments (Traction Circuit).........................................................................................274 Accelerator Control.................................................................................................................277 SCR CONTROL (HYDRAULIC PUMP MOTOR)......................................................................................................277 CONTACTORS..............................................................................................................................278 CIRCUIT PROTECTION......................................................................................................................279 Traction Circuit Fuse...............................................................................................................279 Current Limit.......................................................................................................................279 Thermal Protection..................................................................................................................279 Suppressors.........................................................................................................................279 TRUCK MANAGEMENT MODULE (TMM1)..........................................................................................................279 TABLE 8. Terminal And Plug Wire Connections For TMM1 Module.........................................................................280 DISPLAY PANELS..........................................................................................................................280 Display Panel.......................................................................................................................280 Basic Display.......................................................................................................................280 Performance Display.................................................................................................................282 Brush Wear Indicators...............................................................................................................285 EV-100ZX SCR MOTOR CONTROLLER, Parameter Tables.............................................................................................286 REGISTER PARAMETERS.....................................................................................................................286 General.............................................................................................................................286 Function Numbers....................................................................................................................287 CONTROL CARD, CHECKS AND ADJUSTMENTS....................................................................................................287 REGISTER PARAMETERS.....................................................................................................................287 TABLE 1. EV-100ZX Parameters - E/J2.00-3.20XM (E/J45-65XM) and N30XMH (36 to 48V)(Traction Card Type ZH With Regenerative Brakin....288 TABLE 2. EV-100ZX Parameters - E2.00-3.20XM (E45-65XM) and N30XMH (36 to 48V)(Traction Card Type ZY NO Regenerative Braking and ....291 TABLE 3. EV-100ZX Parameters - E/J2.00-3.20XM (72 to 80V)(Traction Card Type ZH with Regenerative Braking and Field Weakening.......294 TABLE 4. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V)(Traction Card Type ZY With Regenerative Braking And NO Field Weakening......297 TABLE 5. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V)(Low Energy Usage)(Traction Card Type ZY With 9-inch Motor, Regenerative.....300 TABLE 6. EV-100ZX Parameters - All Lift Trucks (36 to 48 volts)(Hydraulic Pump Card Type ZP)........................................303 TABLE 7. EV-100ZX Parameters - All Lift Trucks (72 to 80 volts)(Hydraulic Pump Card Type ZP)........................................306 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers....................................309 COMPUTER SYSTEM.........................................................................................................................309 Connect A PC To A Control Card......................................................................................................310 HYTECt SOFTWARE PROGRAM ................................................................................................................311 How To Start The Program............................................................................................................311 Selecting The Communications Port...................................................................................................312 Verification Of Controller and Lift Truck...........................................................................................312 Select The Lift Truck Series........................................................................................................313 Undefined Controller Card...........................................................................................................314 Controller Card Register Parameter List.............................................................................................314 How To Enter A New Parameter........................................................................................................315 How To Save A Changed Parameter File................................................................................................316 How To Load A Saved Parameter File..................................................................................................316 How To Return To Factory Default Settings...........................................................................................317 How To Save Changes To The Controller Card..........................................................................................318 How To View The Status Codes .......................................................................................................318 Saving The Status Code To Disk......................................................................................................319 Closing and Clearing The Status Code List...........................................................................................320 COMMUNICATIONS PROGRAM (MODEM)..........................................................................................................320 Requirements........................................................................................................................321 README File.........................................................................................................................322 GE Sentry Software......................................................................................................................322 Getting Started.....................................................................................................................322 Where To Get Help...................................................................................................................323 Hardware and Software Requirements..................................................................................................323 Installation of the GE SENTRY SOFTWARE..............................................................................................323 How To Start The GE SENTRY Program..................................................................................................323 How To Reset The MIN and MAX Display................................................................................................325 How To Exit The GE SENTRY Program...................................................................................................325 INTRODUCTION................................................................................................................................326 GENERAL.................................................................................................................................326 DESCRIPTION.............................................................................................................................326 Main Frame..........................................................................................................................326 Other Frame Weldments...............................................................................................................326 Battery Restraint/Hood Frame And Plate For Optional Seat Brake......................................................................328 Overhead Guard......................................................................................................................329 REPAIRS.....................................................................................................................................330 OVERHEAD GUARD..........................................................................................................................330 Removal.............................................................................................................................330 Installation........................................................................................................................330 BATTERY RESTRAINT AND SEAT ASSEMBLY.....................................................................................................330 COUNTERWEIGHT...........................................................................................................................331 Removal.............................................................................................................................331 Installation........................................................................................................................332 TRACTION MOTOR..........................................................................................................................332 Removal.............................................................................................................................332 Installation........................................................................................................................334 HYDRAULIC TANK..........................................................................................................................334 Inspection..........................................................................................................................334 Repairs, Small Leaks................................................................................................................334 Repairs, Large Leaks................................................................................................................335 Cleaning............................................................................................................................335 Steam Method Of Cleaning............................................................................................................335 Chemical Solution Method Of Cleaning................................................................................................335 Additional Preparations For Repair..................................................................................................336 PAINTING INSTRUCTIONS...................................................................................................................337 LABEL REPLACEMENT.......................................................................................................................338 INTRODUCTION................................................................................................................................340 GENERAL.................................................................................................................................340 DESCRIPTION.............................................................................................................................341 Hydraulic System....................................................................................................................341 OPERATION...............................................................................................................................341 Hydraulic System....................................................................................................................341 Hydraulic Gear Pump.................................................................................................................342 Rotator Actuator Valve..............................................................................................................342 Steering Pump.......................................................................................................................345 REPAIRS.....................................................................................................................................349 HYDRAULIC TANK..........................................................................................................................349 E1.50-3.20XM (E25-65XM) and N30XMH Tank Removal.....................................................................................349 J2.00-3.20XM (J40-65XM) Tank Removal................................................................................................349 Tank Inspection.....................................................................................................................349 Tank Repairs, Small Leaks...........................................................................................................350 Tank Repairs, Large Leaks ..........................................................................................................350 Tank Cleaning.......................................................................................................................350 Steam Method Of Cleaning Tank.......................................................................................................350 Chemical Solution Method Of Cleaning Tank...........................................................................................350 Additional Preparations For Tank repair.............................................................................................351 E1.50-3.20XM (E25-65XM) And N30XMH Tank Installation................................................................................351 J2.00-3.20XM (J40-65XM) Tank Installation...........................................................................................351 FILTER REPLACEMENT......................................................................................................................352 HYDRAULIC PUMP..........................................................................................................................352 Removing E1.50-3.20XM (E25-65XM) and N30XMH Hydraulic Pump..........................................................................352 Remove The J2.00-3.20XM (J40-65XM) Hydraulic Pump...................................................................................353 Pump Seal Replacement And Pump Assembly.............................................................................................353 Assemble Pump On The Motor..........................................................................................................355 Install The Hydraulic Pump And Motor Assembly [E1.50-3.20XM (E25-65XM) and N30XMH]..................................................356 Install J2.00-3.20XM (J40-65XM) Hydraulic Pump And Motor Assembly...................................................................356 MAIN CONTROL VALVE......................................................................................................................357 STEERING PUMP...........................................................................................................................357 Pump Removal And Disassembly, E1.50-3.20XM (E25-65XM) and N30XMH....................................................................357 Pump Removal And Disassembly, J2.00-3.20XM (J40-65XM)...............................................................................358 Pump Assembly And Installation......................................................................................................359 ROTARY ACTUATOR VALVE...................................................................................................................360 Disassembly, Cleaning and Inspection................................................................................................360 Assembly............................................................................................................................360 STEERING CONTROL UNIT...................................................................................................................360 Control Unit Removal................................................................................................................361 Control Unit Installation...........................................................................................................361 STEERING CYLINDER.......................................................................................................................361 CHECKS AND ADJUSTMENTS......................................................................................................................363 MAIN CONTROL VALVE......................................................................................................................363 STEERING RELIEF VALVE...................................................................................................................363 TROUBLESHOOTING CHART.......................................................................................................................363 SPECIFICATIONS..............................................................................................................................367 INTRODUCTION................................................................................................................................370 GENERAL.................................................................................................................................370 LEAD-ACID BATTERIES.....................................................................................................................370 SPECIFIC GRAVITY........................................................................................................................371 CHEMICAL REACTION IN A CELL.............................................................................................................371 ELECTRICAL TERMS........................................................................................................................372 HOW TO SELECT THE BATTERY...............................................................................................................372 VOLTAGE OF A BATTERY....................................................................................................................372 THE BATTERY AS A COUNTERWEIGHT..........................................................................................................373 BATTERY RATINGS.........................................................................................................................373 Kilowatt-Hours......................................................................................................................374 BATTERY MAINTENANCE.........................................................................................................................374 SAFETY PROCEDURES.......................................................................................................................374 MAINTENCE RECORDS.......................................................................................................................375 THE NEW BATTERY.........................................................................................................................375 HOW TO CLEAN THE BATTERY................................................................................................................376 HOW TO ADD WATER........................................................................................................................376 THE HYDROMETER..........................................................................................................................377 BATTERY TEMPERATURE.....................................................................................................................377 CHARGING THE BATTERY....................................................................................................................378 Types Of Battery Charges............................................................................................................379 Methods Of Charging.................................................................................................................380 Troubleshooting The Charger.........................................................................................................380 How to Know When The Battery Is Fully Charged.......................................................................................381 WHERE TO CHARGE THE BATTERIES...........................................................................................................381 Equipment Needed....................................................................................................................381 BATTERY CONNECTORS......................................................................................................................382 BATTERY CARE............................................................................................................................382 INTRODUCTION................................................................................................................................384 GENERAL.................................................................................................................................384 DESCRIPTION.............................................................................................................................384 REPAIRS.....................................................................................................................................388 REMOVAL AND DISASSEMBLY.................................................................................................................388 ASSEMBLY AND INSTALLATION...............................................................................................................388 INTRODUCTION................................................................................................................................391 GENERAL.................................................................................................................................391 DESCRIPTION.............................................................................................................................391 Lower Control Valve.................................................................................................................392 REPAIRS.....................................................................................................................................393 MAIN CYLINDER - DISASSEMBLY.............................................................................................................393 MAIN CYLINDER - ASSEMBLY................................................................................................................394 FREE-LIFT CYLINDER - DISASSEMBLY........................................................................................................395 FREE-LIFT CYLINDER - ASSEMBLY...........................................................................................................396 TROUBLESHOOTING.............................................................................................................................397 INTRODUCTION................................................................................................................................400 GENERAL.................................................................................................................................400 DESCRIPTION.............................................................................................................................400 OPERATION...............................................................................................................................401 Lift Section (See FIGURE 3.)............................................................................................................402 Auxiliary Section.......................................................................................................................402 Relief Valve (See FIGURE 5.)............................................................................................................403 REPAIRS.....................................................................................................................................404 MAIN CONTROL VALVE......................................................................................................................404 Removal (See FIGURE 8. And FIGURE 9.)...................................................................................................404 Disassembly (See FIGURE 6.).............................................................................................................405 Cleaning And Inspection.................................................................................................................405 Assembly (See FIGURE 6.)................................................................................................................405 Installation, (See FIGURE 7. And FIGURE 8.).............................................................................................405 CONTROL LEVER LINKAGE...................................................................................................................407 Removal (See FIGURE 9.).................................................................................................................407 Disassembly (See FIGURE 9.).............................................................................................................407 Assembly And Installation (See FIGURE 9.)...............................................................................................407 CONTROL VALVE LINKAGE...................................................................................................................410 Removal And Disassembly (See FIGURE 10.)................................................................................................410 Assembly And Installation (See FIGURE 10.)..............................................................................................410 CHECKS AND ADJUSTMENTS......................................................................................................................411 PRESSURE RELIEF VALVES..................................................................................................................411 Primary Relief Valve (See FIGURE 12.)...................................................................................................411 Secondary Relief Valve (See FIGURE 12.).................................................................................................412 TROUBLESHOOTING.............................................................................................................................412 TROUBLESHOOTING.............................................................................................................................413 INTRODUCTION................................................................................................................................415 GENERAL.................................................................................................................................415 SERIAL NUMBER DATA......................................................................................................................415 HOW TO MOVE A DISABLED LIFT TRUCK.......................................................................................................415 How To Tow A Lift Truck.............................................................................................................415 HOW TO PUT A LIFT TRUCK ON BLOCKS.......................................................................................................416 How To Raise The Drive Tires........................................................................................................416 How To Raise The Steering Tires.....................................................................................................416 MAINTENANCE SCHEDULE........................................................................................................................417 MAINTENANCE PROCEDURES......................................................................................................................419 EVERY 8 HOURS OR DAILY......................................................................................................................419 HOW TO MAKE CHECKS WITH THE KEY OFF.....................................................................................................419 Tires And Wheels....................................................................................................................419 Forks...............................................................................................................................420 Fork Adjustment.....................................................................................................................420 Fork Removal........................................................................................................................420 Fork Installation...................................................................................................................420 Inspection Of Forks, Attachment, Mast, And Lift Chains..............................................................................420 Safety Labels.......................................................................................................................422 Steering Column Latch...............................................................................................................422 Operator Restraint System...........................................................................................................422 Battery Restraint System............................................................................................................422 Battery.............................................................................................................................423 Hydraulic System....................................................................................................................424 HOW TO MAKE CHECKS WITH THE KEY ON......................................................................................................424 Gauges, Horn And Fuses..............................................................................................................424 Steering System.....................................................................................................................424 Service Brakes......................................................................................................................424 Parking Brake.......................................................................................................................425 Control Levers And Pedals...........................................................................................................425 Lift System Operation...............................................................................................................425 EVERY 350 HOURS OR TWO MONTHS...............................................................................................................426 HYDRAULIC TANK BREATHER.................................................................................................................426 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................426 WHEEL NUT TORQUES.......................................................................................................................426 STEERING AXLE SPINDLES..................................................................................................................426 MAST....................................................................................................................................426 LIFT CHAINS.............................................................................................................................427 Check For Wear......................................................................................................................427 Lubrication.........................................................................................................................427 FORKS...................................................................................................................................427 BRAKE FLUID.............................................................................................................................428 OTHER LUBRICATION.......................................................................................................................428 SEAT BRAKE..............................................................................................................................428 ELECTRICAL INSPECTION...................................................................................................................428 CONTACTORS..........................................................................................................................429 MOTOR BRUSHES.......................................................................................................................429 Motor Brushes, General..............................................................................................................429 EVERY 2000 HOURS OR YEARLY..................................................................................................................434 HYDRAULIC SYSTEM........................................................................................................................434 Change The Filter For The Hydraulic Oil.............................................................................................434 Change The Hydraulic Oil............................................................................................................434 DIFFERENTIAL AND SPEED REDUCER..........................................................................................................434 SERVICE BRAKES..........................................................................................................................434 CONTACTORS..............................................................................................................................435 WHEEL BEARINGS..........................................................................................................................435 Steering Wheels, Lubrication........................................................................................................435 Drive Wheels, Lubrication...........................................................................................................435 LIFT CHAINS.............................................................................................................................435 GENERAL PROCEDURES..........................................................................................................................436 HOW TO CHARGE THE BATTERY...............................................................................................................436 HOW TO CHARGE THE BATTERY...............................................................................................................437 General.............................................................................................................................437 Changing The Battery....................................................................................................................437 CHECK FOR LEAKS IN THE HYDRAULIC SYSTEM.................................................................................................439 Check The Cylinders For Leaks.......................................................................................................439 LIFT CHAIN ADJUSTMENTS..................................................................................................................439 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................................440 HOW TO CHECK THE PMT CIRCUIT............................................................................................................441 WELDING REPAIRS.........................................................................................................................442 CHANGES TO THE OVERHEAD GUARD...........................................................................................................442 TIRES AND WHEELS........................................................................................................................442 Removing Wheels From The Lift Truck.................................................................................................442 Remove And Install The Tire On The Wheel............................................................................................442 INTRODUCTION................................................................................................................................445 NOMENCLATURE, THREADS...................................................................................................................445 STRENGTH IDENTIFICATION.................................................................................................................446 TABLE 1. BOLTS AND SCREWS...................................................................................................................446 TABLE 2. STUDS AND NUTS.....................................................................................................................447 TABLE 3. TORQUE NUTS........................................................................................................................448 TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................................449 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................................450 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................................451 INTRODUCTION................................................................................................................................454 GENERAL.................................................................................................................................454 DESCRIPTION.............................................................................................................................454 REPAIRS.....................................................................................................................................455 STEERING AXLE ASSEMBLY..................................................................................................................455 Removal.............................................................................................................................455 Installation........................................................................................................................455 WHEELS..................................................................................................................................455 Removal And Disassembly.............................................................................................................455 Cleaning............................................................................................................................455 Assembly And Installation...........................................................................................................456 SPINDLES, BEARINGS, AND TIE RODS........................................................................................................456 Removal And Disassembly.............................................................................................................456 Assembly And Installation...........................................................................................................457 STEERING CYLINDER.......................................................................................................................458 Removal And Disassembly.............................................................................................................458 Cleaning And Inspection.............................................................................................................458 Assembly And Installation...........................................................................................................458 TROUBLESHOOTING.............................................................................................................................459 TORQUE SPECIFICATIONS.......................................................................................................................459 INTRODUCTION................................................................................................................................461 GENERAL.................................................................................................................................461 DESCRIPTION.............................................................................................................................461 OPERATION...............................................................................................................................461 REPAIRS.....................................................................................................................................462 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................462 Removal of the Assembly Components..................................................................................................466 Disassembly of the Steering Control Unit............................................................................................467 Cleaning of the Steering Control Unit...............................................................................................467 Assembly of the Steering Control Unit...............................................................................................467 Installation of the Steering Control Unit...........................................................................................467 Installation of the Assembly Components.............................................................................................467 CHECKS AND ADJUSTMENTS......................................................................................................................475 REMOVE AIR FROM THE SYSTEM..............................................................................................................475 TROUBLESHOOTING.............................................................................................................................475 STEERING SYSTEM.............................................................................................................................477 GENERAL.................................................................................................................................477 DESCRIPTION.............................................................................................................................479 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................................480 Removal Of The Assembly Components..................................................................................................480 Installation Of The Assembly Components.............................................................................................484 POWER STEERING MOTOR AND PUMP...............................................................................................................485 DESCRIPTION.............................................................................................................................485 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)......................................485 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3)...........................................................................485 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)........................................................................................486 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL).......................................................................................488 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)......................................................................................489 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]..........................................489 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)......................................................................................490 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)....................................................................................492 REPAIRS, POWER STEERING PUMP............................................................................................................493 Seal Replacement....................................................................................................................494 HYDRAULIC STEERING MOTOR....................................................................................................................494 DESCRIPTION.............................................................................................................................494 REPAIRS, HYDRAULIC STEERING MOTOR.......................................................................................................495 Removal ............................................................................................................................495 Disassembly.........................................................................................................................495 Cleaning And Inspection.............................................................................................................495 Assembly............................................................................................................................496 Installation, Hydraulic Steering Motor..............................................................................................497 CHECKS AND ADJUSTMENTS......................................................................................................................497 AIR IN THE STEERING SYSTEM..............................................................................................................497 CHECK STEERING PRESSURE.................................................................................................................497 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only)...........................................................................498 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS...........................................................................................499 TROUBLESHOOTING.............................................................................................................................501 INTRODUCTION................................................................................................................................504 GENERAL.................................................................................................................................504 MAST WELDMENTS..........................................................................................................................505 CARRIAGES...............................................................................................................................506 VISTA TWO-STAGE MAST........................................................................................................................506 DESCRIPTION.............................................................................................................................506 OPERATION...............................................................................................................................508 VISTA THREE-STAGE MAST......................................................................................................................509 DESCRIPTION.............................................................................................................................509 OPERATION...............................................................................................................................511 INTRODUCTION................................................................................................................................516 General.................................................................................................................................516 SAFETY PROCEDURES...........................................................................................................................516 LOAD BACKREST EXTENSION, CARRIAGE, LOAD ROLLERS, SIDE ROLLERS AND FORKS.....................................................................517 Load Backrest Extension - Removal And Installation......................................................................................517 Carriage Assembly - Removal And Installation............................................................................................518 Carriage Load Rollers - Removal And Installation........................................................................................520 Side Rollers - Disassembly And Assembly.................................................................................................521 Fork Replacement........................................................................................................................521 Forks - Carriage....................................................................................................................521 Forks - Reach Carriage..............................................................................................................522 TWO-STAGE MAST ASSEMBLY.....................................................................................................................522 Two-Stage Mast Assembly - Removal.......................................................................................................522 Cleaning And Inspection.................................................................................................................523 Lift Cylinders - Removal And Installation...............................................................................................525 Inner Mast Assembly - Removal And Installation..........................................................................................527 Hoses - Replace.........................................................................................................................527 Hoses And Cable Sheaves - Replace.......................................................................................................527 Two-Stage Lift Chains...................................................................................................................528 Removal And Installation............................................................................................................528 Cleaning And Inspection.............................................................................................................528 Two-Stage Chain Sheave - Removal And Installation.......................................................................................528 Load Rollers And Wear Plugs - Removal And Installation..................................................................................529 Two-Stage Mast Assembly - Installation..................................................................................................530 THREE-STAGE MAST ASSEMBLY...................................................................................................................531 Three-Stage Mast Assembly - Removal.....................................................................................................531 Cleaning And Inspection.................................................................................................................532 Free-Lift Cylinder - Removal And Installation...........................................................................................534 Inner And Intermediate Mast Assemblies - Removal And Installation.......................................................................537 Hoses - Replace.........................................................................................................................538 Hose And Cable Sheaves - Replace........................................................................................................538 Free-Lift Hose Sheave...............................................................................................................540 Carriage Sheaves....................................................................................................................540 Three-Stage Lift Chains - Removal And Installation......................................................................................540 General.............................................................................................................................540 Free-Lift Chains....................................................................................................................540 Main-Lift Chains....................................................................................................................541 Three-Stage Chain Sheaves - Diassembly And Assembly.....................................................................................541 Free-Lift Chain Sheaves.............................................................................................................541 Main-Lift Chain Sheaves.............................................................................................................541 Load Rollers And Wear Plugs - Removal And Installation..................................................................................542 Three-Stage Mast Assembly - Installation................................................................................................543 CHECKS AND ADJUSTMENTS......................................................................................................................544 Check The Operation Of The Mast.........................................................................................................544 Check For Leaks In The Hydraulic System.................................................................................................544 Check Lift Chains.......................................................................................................................545 General.............................................................................................................................545 Cleaning And Inspection.............................................................................................................545 Lubrication.........................................................................................................................545 Mast Adjustments........................................................................................................................546 General.............................................................................................................................546 Adjust Wear Plugs - Mast............................................................................................................546 Adjust Free-Lift Chains (Three-Stage Only)..........................................................................................547 Adjust Main-Lift Chains.............................................................................................................548 Adjust Wear Strips..................................................................................................................549 Carriage Adjustments....................................................................................................................550 Adjust Wear Plugs - Carriage........................................................................................................550 Adjust Side Rollers - Carriage......................................................................................................551 Adjust Thrust Rollers - Carriage....................................................................................................551
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]
