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HysterE70 120XL₃ service manual – PDF DOWNLOAD
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Description
HysterE70 120XL₃ service manual
File Details:
HysterE70 120XL₃ service manual
Language : English
Pages : 489
Size : 15.3 MB
Downloadable : Yes
Format : PDF
HYSTERE70 120XL₃ SERVICE MANUAL – PDF DOWNLOAD:
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Description:
HysterE70 120XL₃ service manual
Table of Contents:
HysterE70 120XL₃ service manual
BRAKE SYSTEM............................................................................................................ 1 GENERAL............................................................................................................. 1 DESCRIPTION AND OPERATION........................................................................................... 1 BRAKE BOOSTER AND MASTER CYLINDER................................................................................... 1 MASTER CYLINDER..................................................................................................... 1 BRAKE SERVICE ASSEMBLY.............................................................................................. 3 PARKING BRAKE....................................................................................................... 4 REPAIRS................................................................................................................. 4 BRAKE SHOE ASSEMBLIES............................................................................................... 4 Removal and Disassembly......................................................................................... 4 Cleaning and Inspection......................................................................................... 5 Assembly and Installation....................................................................................... 7 MASTER CYLINDER, S3.50-5.50XL (S70-120XL) and H3.50-5.00XL (H70-110XL).............................................. 10 Removal......................................................................................................... 10 Disassembly..................................................................................................... 10 Assembly........................................................................................................ 11 Installation.................................................................................................... 11 MASTER CYLINDER, E3.50-5.50L (E70-120XL, E70-120XL3)................................................................ 11 Removal and Disassembly......................................................................................... 11 Cleaning and Inspection......................................................................................... 12 Assembly and Installation....................................................................................... 12 BRAKE BOOSTER....................................................................................................... 12 Removal......................................................................................................... 12 Disassembly..................................................................................................... 12 Cleaning and Inspection......................................................................................... 13 Assembly........................................................................................................ 13 Installation.................................................................................................... 14 CHECKS AND ADJUSTMENTS.................................................................................................. 14 REMOVE THE AIR FROM THE BRAKE SYSTEM................................................................................ 14 ADJUST THE BRAKE PEDAL, H3.50-5.00XL (H70-110XL) With Manual Transmission and E3.50-5.50 (E70-120XL, E70-120XL3).... 14 ADJUST THE BRAKE SHOES.............................................................................................. 16 ADJUST THE PARKING BRAKE, S3.50-5.50XL (S70-120XL) H3.50-5.00XL (H70-110XL)......................................... 17 ADJUST THE PARKING BRAKE LEVER AND SWITCH, E3.50-5.50XL (E70-120XL, E70-120XL3)..................................... 17 CHECK THE RELIEF VALVE ON THE BRAKE BOOSTER......................................................................... 17 TROUBLESHOOTING......................................................................................................... 18 LIFT TRUCK WEIGHTS...................................................................................................... 20 TIRE SIZES.............................................................................................................. 20 CAPACITIES.............................................................................................................. 20 HYDRAULIC SYSTEM........................................................................................................ 20 MAST SPEEDS ............................................................................................................ 21 MAST CREEP SPEEDS....................................................................................................... 22 BATTERY SPECIFICATIONS.................................................................................................. 22 TRACTION SPEED AND TRACTION MOTOR CURRENT............................................................................... 23 HOIST MOTOR CURRENT..................................................................................................... 23 TORQUE SPECIFICATIONS................................................................................................... 24 INTRODUCTION............................................................................................................ 25 ELECTRIC MOTOR MAINTENANCE, GENERAL................................................................................. 25 BRUSH AND COMMUNICATOR INSPECTION................................................................................... 25 Hydraulic Pump Motor And Traction Motor......................................................................... 25 Steering Pump Motor............................................................................................. 27 BRUSH WEAR REPLACEMENT GUIDE............................................................................................ 27 Commutator Problems................................................................................................. 29 BRUSH REPLACEMENTS.................................................................................................. 31 DISASSEMBLY OF MOTORS............................................................................................... 33 Traction Motor And Hydraulic Pump Motor......................................................................... 33 Steering Pump Motor............................................................................................. 39 ASSEMBLY OF MOTORS.................................................................................................. 41 Traction Motor And Hydraulic Pump Motor ........................................................................ 41 Steering Pump Motor............................................................................................. 41 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS...................................................................... 41 TESTS FOR A DAMAGED FIELD AND ARMATURE.............................................................................. 42 Test For An Open Circuit In The Armature........................................................................ 42 Test For A Short-Circuit In One Armature Winding................................................................ 42 Test For A Short-Circuit To Armature Shaft...................................................................... 43 Test For An Open Circuit In A Field Coil........................................................................ 43 Test For A Short-Circuit In A Field Coil........................................................................ 43 Test For A Short-Circuit Between The Field And The Motor Case................................................... 44 Brush Holder Test............................................................................................... 44 TROUBLESHOOTING......................................................................................................... 44 FIGURE 1. SCHEMATIC DIAGRAM FOR THE SEM CONTROLS........................................................................ 46 FIGURE 2. WIRING DIAGRAM FOR THE SEM CONTROLS .......................................................................... 49 FIGURE 3. WIRING CONNECTOR ARRANGEMENTS................................................................................. 53 FIRGUE 4. SCHEMATIC DIAGRAM FOR THE LIGHTS.............................................................................. 54 FIGURE 5. HYDRAULIC SCHEMATIC........................................................................................... 56 DRIVE AXLE.............................................................................................................. 57 GENERAL............................................................................................................. 57 DESCRIPTION......................................................................................................... 57 REPAIRS................................................................................................................. 58 REMOVAL............................................................................................................. 58 General......................................................................................................... 58 Traction Motor, Speed Reducer, and Differential................................................................. 58 DISASSEMBLY......................................................................................................... 61 Speed Reducer................................................................................................... 61 Differential.................................................................................................... 61 CLEANING............................................................................................................ 61 INSPECTION.......................................................................................................... 61 ASSEMBLY............................................................................................................ 62 Speed Reducer................................................................................................... 62 ADJUSTMENTS OF SHIMS FOR THE PINION ASSEMBLY........................................................................ 63 Differential.................................................................................................... 64 DRIVE AXLE HOUSING.................................................................................................. 65 Removal......................................................................................................... 65 Cleaning........................................................................................................ 67 Inspection...................................................................................................... 67 Assembly........................................................................................................ 67 TROUBLESHOOTING......................................................................................................... 70 ELECTRICAL SYSTEM....................................................................................................... 71 GENERAL............................................................................................................. 71 "LX" SERIES DISPLAY PANEL........................................................................................... 72 Hourmeter Functions............................................................................................. 73 Battery Indicator Function...................................................................................... 73 Status Code Function............................................................................................ 74 "ZX" SERIES DISPLAY PANELS.......................................................................................... 74 Display Panel................................................................................................... 74 Basic Display Panels............................................................................................ 74 Performance Display............................................................................................. 76 Brush Wear Indicators........................................................................................... 79 SEM DISPLAY PANELS - FEATURES....................................................................................... 79 Description Of Common Features.................................................................................. 80 LED SYMBOL INDICATORS........................................................................................... 80 LCD SCREEN...................................................................................................... 80 BATTERY DISCHARGE INDICATOR (BDI)............................................................................... 80 SERVICE REMINDER................................................................................................ 80 STATUS CODES.................................................................................................... 80 HOURMETER....................................................................................................... 80 Additional Features Of Premium Display Panel ................................................................... 80 Descriptions Of Additional Features (Available With The Premium Display) ....................................... 81 LCD SCREEN...................................................................................................... 81 OPERATOR PASSWORDS.............................................................................................. 81 DAILY CHECK LIST AND SERVICE ITEMS.............................................................................. 81 PERFORMANCE MODELS.............................................................................................. 81 STATUS CODE LISTS............................................................................................... 81 ADJUSTMENTS OF BDI.............................................................................................. 82 SEM DISPLAY PANEL INDICATORS........................................................................................ 82 All Indicator Symbols........................................................................................... 82 Hourmeter Indicator Symbol...................................................................................... 83 Wrench Indicator Symbol......................................................................................... 83 Battery Indicator Symbol........................................................................................ 83 Battery State-Of-Charge (BDI)................................................................................... 83 Brake Fluid Too Low Symbol...................................................................................... 83 Parking Brake Symbol............................................................................................ 83 Fasten Seat Belt Symbol......................................................................................... 83 LCD "Screen" (Standard Display Panel)........................................................................... 83 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL -SEM............................................................. 83 Alpha Numeric "Screen".......................................................................................... 83 "Star" Push Button.............................................................................................. 84 Push Buttons #1 Through #5...................................................................................... 84 OTHER CONTROL COMPONENTS............................................................................................ 84 REPLACEMENT............................................................................................................. 85 DISPLAY PANEL COMPONENTS - "LX" AND "ZX"............................................................................ 85 Replace The Display Panel Assembly.............................................................................. 85 Replace The Key Switch.......................................................................................... 86 Indicator LEDs.................................................................................................. 86 Battery Indicators.............................................................................................. 86 Digital Display (Performance Display Panel Only) ............................................................... 86 Status Code Or Performace Level Switches And Indicator LEDs (Performance Display Panel Only).................... 88 Replace Parts Of The Basic Display Panel ....................................................................... 88 Replace Parts Of The Performance Display Panel.................................................................. 89 SEM DISPLAY PANEL................................................................................................... 90 Removal And Replacement......................................................................................... 90 REPLACE MOTOR CONTROLLER (SR or SP)................................................................................. 90 OTHER CONTROL COMPONENTS............................................................................................ 90 Start Swtich.................................................................................................... 90 Brake Light Switch.............................................................................................. 91 Seat Switch..................................................................................................... 92 Adjust The External Seat Switch................................................................................. 93 Switch For Optional Seat Brake.................................................................................. 93 Parking Brake Switch............................................................................................ 93 Direction Switches (Monotrol Pedal)............................................................................ 94 Direction Control Switches (Steering Column).................................................................... 95 Direction Control Switches, E70-120XL3 (Steering Column)........................................................ 96 Brake Fluid Switch.............................................................................................. 96 Brush Wear And Over Temperature Sensors......................................................................... 96 Rocker Switches For Lights ..................................................................................... 97 Accelerator Position Sensor..................................................................................... 97 On-Demand Steering Components................................................................................... 99 Lights, Converter, Relay And Reverse Alarm......................................................................101 Horn And Horn Buttons...........................................................................................104 Hydraulic Pump Switches.........................................................................................105 CHECKS AND ADJUSTMENTS..................................................................................................105 GENERAL.............................................................................................................105 CONTROL AND POWER FUSES - "LX" OR "ZX"..............................................................................105 CONTROL AND POWER FUSES - SEM.......................................................................................108 CHECK BRUSH WEAR AND OVER TEMPERATURE SENSORS - "LX" OR "ZX"........................................................111 THERMAL SENSORS - SEM...............................................................................................111 ADJUST THE START SWITCH.............................................................................................111 Accelerator Potentiometer And Start Switch, E20-120XL, E70-120XL3...............................................112 Direction Switches (MONOTROL)...................................................................................114 ADJUST THE BRAKE LIGHT SWITCH...................................................................................114 CHECK SEAT SWITCH...............................................................................................114 ADJUST THE SWITCH FOR OPTIONAL SEAT BRAKE.......................................................................114 ADJUST THE PARKING BRAKE SWITCH.................................................................................115 DIRECTIONAL SWITCHES............................................................................................115 DIRECTIONAL SWITCHES (STEERING COLUMN)..........................................................................115 HYDRAULIC PUMP SWITCHES.........................................................................................115 MONOTROL PEDAL OR ACCELERATOR PEDAL ADJUSTMENT..................................................................115 ADJUST THE ACCELERATOR POSITION SENSOR..........................................................................116 FRAME...................................................................................................................118 GENERAL.............................................................................................................118 DESCRIPTION.........................................................................................................118 BATTERY SPECIFICATIONS..................................................................................................120 REPAIRS.................................................................................................................123 OVERHEAD GUARD......................................................................................................123 Removal.........................................................................................................123 Installation....................................................................................................123 BATTERY RESTRAINT AND SEAT ASSEMBLY.................................................................................124 COUNTERWEIGHT.......................................................................................................128 Removal.........................................................................................................128 Installation....................................................................................................128 TRACTION MOTOR......................................................................................................129 Removal.........................................................................................................129 Installation....................................................................................................130 HYDRAULIC TANK......................................................................................................131 Inspection......................................................................................................131 Repairs, Small Leaks............................................................................................131 Repairs, Large Leaks............................................................................................131 Cleaning........................................................................................................131 Steam Method Of Cleaning........................................................................................131 Chemical Solution Method Of Cleaning............................................................................132 Additional Preparations For Repair..............................................................................132 PAINTING INSTRUCTIONS...............................................................................................132 LABEL PLACEMENT.....................................................................................................133 HYDRAULIC SYSTEM........................................................................................................139 GENERAL.............................................................................................................139 DESCRIPTION.........................................................................................................139 Hydraulic System................................................................................................139 OPERATION...........................................................................................................140 Hydraulic System................................................................................................140 Hydraulic Pump..................................................................................................141 Steering Pump...................................................................................................142 REPAIRS.................................................................................................................142 HYDRAULIC PUMP......................................................................................................142 Removal.........................................................................................................142 Seal Placement..................................................................................................143 Installation....................................................................................................144 CHECKS AND ADJUSTMENTS..................................................................................................144 MAIN CONTROL VALVE..................................................................................................144 Linkage And Switches............................................................................................144 Relief Valve....................................................................................................145 STEERING RELIEF VALVE ..............................................................................................146 TROUBLESHOOTING.........................................................................................................148 SPECIFICATIONS..........................................................................................................149 INTRODUCTION............................................................................................................150 GENERAL.............................................................................................................150 LEAD-ACID BATTERIES.................................................................................................150 SPECIFIC GRAVITY....................................................................................................151 CHEMICAL REACTION IN A CELL.........................................................................................151 ELECTRICAL TERMS....................................................................................................152 HOW TO SELECT THE BATTERY...........................................................................................152 VOLTAGE OF A BATTERY................................................................................................152 THE BATTERY AS A COUNTERWEIGHT......................................................................................153 BATTERY RATINGS.....................................................................................................153 Kilowatt-Hours..................................................................................................154 BATTERY MAINTENANCE.....................................................................................................154 SAFETY PROCEDURES...................................................................................................154 MAINTENCE RECORDS...................................................................................................155 THE NEW BATTERY.....................................................................................................155 HOW TO CLEAN THE BATTERY............................................................................................156 HOW TO ADD WATER....................................................................................................156 THE HYDROMETER......................................................................................................157 BATTERY TEMPERATURE.................................................................................................157 CHARGING THE BATTERY................................................................................................158 Types Of Battery Charges........................................................................................159 Methods Of Charging.............................................................................................160 Troubleshooting The Charger.....................................................................................160 How to Know When The Battery Is Fully Charged...................................................................161 WHERE TO CHARGE THE BATTERIES.......................................................................................161 Equipment Needed................................................................................................161 BATTERY CONNECTORS..................................................................................................162 BATTERY CARE........................................................................................................162 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................164 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST........................................................................164 LIFT CYLINDERS..........................................................................................................167 GENERAL.............................................................................................................167 DESCRIPTION.........................................................................................................167 Lowering Control Valve..........................................................................................167 Cylinders (General).............................................................................................170 Cylinders (H520-620B,H700-800A).................................................................................172 Cylinders (H360-460B)...........................................................................................173 Cylinders (Two-Speed)...........................................................................................173 REPAIRS.................................................................................................................174 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..............................................................174 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast........................174 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.........................................178 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder...................................176 DISASSEMBLY.........................................................................................................176 ASSEMBLY............................................................................................................178 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.......................................................................178 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast........................178 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead................................178 CHEVRON PACKING.....................................................................................................179 LIFT CYLINDERS FOR VISTA MASTS..........................................................................................182 DESCRIPTION.........................................................................................................182 Lowering Control Valve..........................................................................................184 REMOVAL.............................................................................................................185 DISASSEMBLY.........................................................................................................185 ASSEMBLY............................................................................................................185 INSTALLATION........................................................................................................186 Main Lift Cylinders.............................................................................................186 Free-Lift Cylinders.............................................................................................186 CHECKS AND ADJUSTMENTS..................................................................................................187 CHECK FOR LEAKS IN LIFT SYSTEM......................................................................................187 TROUBLESHOOTING.........................................................................................................188 SPECIFICATIONS..........................................................................................................189 INTRODUCTION............................................................................................................190 GENERAL.............................................................................................................190 DESCRIPTION.........................................................................................................190 OPERATION...........................................................................................................191 Lift Section....................................................................................................192 Tilt Section....................................................................................................192 Relief Valve....................................................................................................194 SOLENOID VALVE FOR AUXILIARY FUNCTION...............................................................................195 Operation.......................................................................................................195 REPAIRS.................................................................................................................195 MAIN CONTROL VALVE..................................................................................................195 Removal and Disassembly.........................................................................................195 Cleaning and Inspection.........................................................................................196 Assembly........................................................................................................196 Installation....................................................................................................196 SOLENOID VALVE FOR AUXILIARY FUNCTION...............................................................................196 Removal and Disassembly.........................................................................................196 Assembly and Installation.......................................................................................198 CHECKS AND ADJUSTMENTS..................................................................................................198 PRESSURE RELIEF VALVES..............................................................................................198 Primary Relief Valve............................................................................................198 Seconday Relief Valve...........................................................................................199 CONTROL LEVER ARRANGEMENT...........................................................................................199 TROUBLESHOOTING.........................................................................................................202 SPECIFICATIONS..........................................................................................................204 PERIODIC MAINTENANCE....................................................................................................205 GENERAL.............................................................................................................205 SERIAL NUMBER DATA..................................................................................................205 HOW TO MOVE A DISABLED LIFT TRUCK...................................................................................205 How to Tow a Lift Truck.........................................................................................205 HOW TO PUT A LIFT TRUCK ON BLOCKS...................................................................................206 How To Raise the Drive Tires....................................................................................206 How to Raise the Steering Tires.................................................................................206 MAINTENANCE SCHEDULE....................................................................................................207 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY...........................................................................209 HOW TO MAKE CHECKS WITH THE KEY SWITCH OFF..........................................................................209 Tires and Wheels................................................................................................209 Forks...........................................................................................................209 Inspection Of The Mast, Forks And Lift Chains...................................................................210 Safety Labels...................................................................................................211 Steering Column Latch...........................................................................................211 Operator Restraint System.......................................................................................212 Battery Restraint System........................................................................................212 Battery.........................................................................................................213 Hydraulic System................................................................................................214 HOW TO MAKE CHECKS WITH THE KEY SWITCH ON...........................................................................214 Gauges, Horn and Fuses..........................................................................................214 Steering System.................................................................................................214 Service Brakes..................................................................................................214 Parking Brake...................................................................................................215 Control Levers And Pedals.......................................................................................215 Lift System Operation...........................................................................................215 EVERY 350 OR TWO MONTHS.................................................................................................216 HYDRAULIC TANK BREATHER.............................................................................................216 DIFFERENTIAL AND SPEED REDUCER......................................................................................216 WHEEL NUTS..........................................................................................................216 STEERING AXLE SPINDLES..............................................................................................216 MAST................................................................................................................216 LIFT CHAINS.........................................................................................................217 Check For Wear..................................................................................................217 Lubrication.....................................................................................................218 FORKS...........................................................................................................218 BRAKE FLUID.........................................................................................................218 OTHER LUBRICATION...................................................................................................218 SEAT BRAKE..........................................................................................................218 ELECTRICAL INSPECTION...............................................................................................218 Contractors.....................................................................................................219 Motor Brushes...................................................................................................219 EVERY 2000 HOURS OR YEARLY..............................................................................................220 HYDRAULIC SYSTEM....................................................................................................220 Change the Filter for the Hydraulic Oil.........................................................................220 Change the Hydraulic Oil........................................................................................221 DIFFERENTIAL AND SPEED REDUCER......................................................................................221 SERVICE BRAKES......................................................................................................221 CONTRACTORS.........................................................................................................222 WHEEL BEARINGS......................................................................................................222 Steering Wheels, Lubrication....................................................................................222 Drive Wheels, Lubrication.......................................................................................222 LIFT CHAINS.........................................................................................................222 GENERAL PROCEDURES......................................................................................................222 HOW TO CHARGE THE BATTERY...........................................................................................222 HOW TO CHANGE THE BATTERY...........................................................................................223 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)...............................................................227 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)...............................................................228 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.........................................................................228 Check the Lift Cylinders for Leaks..............................................................................228 Check the Tilt Cylinders for Leaks..............................................................................228 LIFT CHAIN ADJUSTMENTS..............................................................................................229 HOW TO CHECK THE PMT CIRCUIT........................................................................................229 WELDING REPAIRS.....................................................................................................230 CHANGES TO THE OVERHEAD GUARD.......................................................................................230 TIRES AND WHEELS....................................................................................................230 General.........................................................................................................230 Remove The Wheels From The Lift Truck...........................................................................231 Remove The Tire From The Wheel And Install Tire On The Wheel....................................................231 Install The Wheels..............................................................................................232 BATTERY SPECIFICATIONS..............................................................................................232 INTRODUCTION............................................................................................................233 NOMENCLATURE, THREADS...............................................................................................233 STRENGTH IDENTIFICATION.............................................................................................234 TABLE 1. BOLTS AND SCREWS...............................................................................................234 TABLE 2. STUDS AND NUTS.................................................................................................235 TABLE 3. TORQUE NUTS....................................................................................................236 TABLE 4. TORQUE NUTS WITH NYLON INSERT..................................................................................237 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...............................................................................238 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.............................................................................239 SEM DISPLAY PANEL.......................................................................................................242 GENERAL.............................................................................................................242 SEM DISPLAY PANEL FEATURES..........................................................................................242 Description Of Common Features..................................................................................242 LED SYMBOL INDICATORS...........................................................................................242 LED SCREEN .....................................................................................................242 BATTERY DISCHARGE INDICATOR (BDI)...............................................................................242 SERVCE REMINDER.................................................................................................243 STATUS CODES....................................................................................................243 HOURMETER.......................................................................................................243 Additional Features Of Premium Display Panel....................................................................243 Descriptions Of Additional Features (Available With The Premium Display)........................................243 LCD SCREEN......................................................................................................243 OPERATOR PASSWORDS..............................................................................................243 DAILY CHECK LIST AND SERVICE ITEMS..............................................................................244 PERFORMANCE MODES...............................................................................................244 STATUS CODES LIST...............................................................................................244 ADJUSTMENT OF BDI...............................................................................................245 SEM DISPLAY PANEL INDICATORS........................................................................................245 All Indicator Symbols...........................................................................................245 Hourmeter Indicator Symbol......................................................................................246 Wrench Indicator Symbol.........................................................................................246 Battery Indicator Symbol........................................................................................246 Battery State-Of-Charge (BDI)...................................................................................246 Brake Fluid Too Low Symbol......................................................................................246 Parking Brake Symbol............................................................................................246 Fasten Seat Belt Symbol.........................................................................................246 LCD Screen (Standard Display Panel).............................................................................246 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL..................................................................246 Alpha Numeric Screen............................................................................................246 "STAR" Push Button..............................................................................................247 Push Buttons #1 Through #5......................................................................................247 ADJUSTMENTS WITH A COMPUTER.........................................................................................248 COMPUTER SYSTEM.................................................................................................248 Connect A PC To The SEM Display Panel...........................................................................248 ITW SWITCHES SOFTWARE PROGRAM (For SEM Display Panel)...........................................................249 Description.................................................................................................249 Where To Get Help...........................................................................................249 Hardware And Software Requirements..........................................................................249 How To Start The ITW SWITCHES Program.......................................................................250 Menus.......................................................................................................250 Create A Setup File.........................................................................................258 REPLACEMENT.........................................................................................................278 GENERAL.........................................................................................................278 SEM DISPLAY PANEL...............................................................................................278 Removal And Replacement ........................................................................................278 TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER For EV-100ZX, EV-T100, SR (SEM) And SP Motor Controllers................281 COMPUTER SYSTEM.....................................................................................................281 Connect A PC To A Control Card..................................................................................282 HYTECt SOFTWARE PROGRAM ............................................................................................283 How To Start The Program........................................................................................283 Selecting The Communications Port...............................................................................284 Verification Of Controller and Lift Truck.......................................................................284 Select The Lift Truck Series....................................................................................285 Undefined Controller Card.......................................................................................286 Controller Card Register Parameter List.........................................................................286 How To Enter A New Parameter....................................................................................287 How To Save A Changed Parameter File............................................................................288 How To Load A Saved Parameter File..............................................................................288 How To Return To Factory Default Settings.......................................................................289 How To Save Changes To The Controller Card......................................................................290 How To View The Status Codes ...................................................................................290 Saving The Status Code To Disk..................................................................................291 Closing and Clearing The Status Code List.......................................................................292 COMMUNICATIONS PROGRAM (MODEM)......................................................................................292 Requirements....................................................................................................293 README File.....................................................................................................294 GE Sentry Software..................................................................................................294 Getting Started.................................................................................................294 Where To Get Help...............................................................................................295 Hardware and Software Requirements..............................................................................295 Installation of the GE SENTRY SOFTWARE..........................................................................295 How To Start The GE SENTRY Program..............................................................................295 How To Reset The MIN and MAX Display............................................................................297 How To Exit The GE SENTRY Program...............................................................................297 TRANSISTOR MOTOR CONTROLLERS (SR AND SP)................................................................................298 DESCRIPTION ........................................................................................................298 Model Number For The Transistor Motor Controllers (SR and SP)...................................................299 MOTOR CONTROLLER, CHECKS AND ADJUSTMENTS............................................................................301 CHECKS AND ADJUSTMENTS USING A HAND SET.............................................................................302 General.........................................................................................................302 Connect The Hand Set............................................................................................303 Start The Sequence..............................................................................................303 Check Or Delete Stored Status Codes.............................................................................303 Returning The Lift Truck To Normal Operation....................................................................304 How To Check And Adjust The Registers...........................................................................307 ADJUSTMENTS - FUNCTION PARAMETERS...................................................................................307 General.........................................................................................................307 Function Numbers................................................................................................308 When The Hand Set Is Connected To A Motor Controller In The Lift Truck..........................................308 FUNCTION NUMBER DESCRIPTIONS........................................................................................309 TRACTION MOTOR CONTROLLER (LABEL LETTER - SR).......................................................................309 FUNCTION WITH PREMIUM DISPLAY PANEL ONLY............................................................................314 PUMP MOTOR CONTROLLER (LABEL LETTER - SP)...........................................................................316 FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY...........................................................................319 TROUBLESHOOTING - STATUS CODES..........................................................................................325 TROUBLESHOOTING.....................................................................................................326 General.........................................................................................................326 Status Codes....................................................................................................326 REPAIRS.................................................................................................................354 GENERAL.............................................................................................................354 GENERAL MAINTENANCE.................................................................................................354 Special Precautions.............................................................................................354 FUSES...............................................................................................................357 CONTRACTORS.........................................................................................................357 Contractor Repair...............................................................................................357 CONTRACTOR DRIVER MODULE............................................................................................359 Replace Contractor Driver.......................................................................................359 MOTOR CONTROLLER PLUG...............................................................................................359 BRUSH WEAR INDICATORS...............................................................................................359 THERMAL SENSORS.....................................................................................................360 REPLACE MOTOR CONTROLLER............................................................................................360 PARAMETER TABLE.........................................................................................................365 GENERAL.............................................................................................................365 Function Numbers................................................................................................365 MOTOR CONTROLLER CHECKS AND ADJUSTMENTS.............................................................................365 PARAMETER TABLES....................................................................................................366 THEORY OF OPERATION.....................................................................................................374 GENERAL.............................................................................................................374 DESCRIPTION of SEM SYSTEM...........................................................................................374 OPERATION OF SEM SYSTEM (SR MOTOR CONTROLLER).......................................................................375 Reverse Circuit.................................................................................................375 Performance and Effeciency......................................................................................375 Field Weakening.................................................................................................376 Regenerative Braking............................................................................................376 Creep Speed.....................................................................................................376 Controlled Acceleration.........................................................................................377 Current Limit...................................................................................................377 BRAKING.............................................................................................................377 Regenerative Braking to Zero Speed..............................................................................377 Pedal Position Braking..........................................................................................377 Auto Braking....................................................................................................377 AUXILIARY SPEED CONTROL.............................................................................................377 Field Weakening.................................................................................................377 Speed Limits....................................................................................................378 RAMP OPERATION......................................................................................................378 Ramp Start......................................................................................................378 Anti-Rollback...................................................................................................378 STEER PUMP CONTRACTOR TIME DELAY....................................................................................378 Coil Drivers And Internal Coil Suppression......................................................................378 SYSTEM PROTECTIVE OVERRIDE..........................................................................................378 SRO (Static Return to Off)......................................................................................378 Accelerator Volts Hold Off......................................................................................378 Pulse Monitor Trip (PMT)........................................................................................378 Thermal Protector (PT)..........................................................................................379 Low Voltage.....................................................................................................379 SP PUMP MOTOR CONTROLLERS...........................................................................................379 CONTRACTOR DRIVER MODULE............................................................................................379 DIAGNOSTICS.........................................................................................................380 Systems Diagnostics.............................................................................................380 Standard Status Codes...........................................................................................380 Stored Status Codes.............................................................................................380 Hourmeter Readings..............................................................................................380 Maintenance Management Capability...............................................................................380 STEERING AXLE...........................................................................................................385 GENERAL.............................................................................................................385 DESCRIPTION.........................................................................................................385 REPAIRS.................................................................................................................386 STEERING AXLE, H3.50-5.50XL (H70-110XL) and S3.50-5.50XL (S70-120XL), E3.50-5.50XL (E70-120XL, E70-120XL3)..........386 Removal.........................................................................................................386 Installation....................................................................................................386 STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360L)..............................................387 Removal....................................................................................................387 Installation................................................................................................388 WHEELS AND HUBS, ALL UNITS......................................................................................388 Removal and Disassembly.........................................................................................388 Cleaning........................................................................................................389 Assembly and Installation.......................................................................................389 SPINDLES AND BEARINGS, ALL UNITS....................................................................................389 Removal.........................................................................................................389 Cleaning........................................................................................................390 Assembly and Installation.......................................................................................390 TIE RODS, ALL UNITS.................................................................................................390 Removal.........................................................................................................390 Cleaning........................................................................................................391 Installation....................................................................................................391 STEERING CYLINDER...................................................................................................392 Removal and Disassembly.........................................................................................392 Cleaning and Inspection.........................................................................................392 Assembly and Installation.......................................................................................392 TROUBLESHOOTING.........................................................................................................393 STEERING CONTROL UNIT...................................................................................................394 GENERAL.............................................................................................................394 DESCRIPTION.........................................................................................................394 Control Valve Section...........................................................................................394 Metering Section................................................................................................394 DISASSEMBLY AND INSPECTION..........................................................................................396 ASSEMBLY............................................................................................................406 TROUBLESHOOTING.........................................................................................................420 STEERING SYSTEM.........................................................................................................421 GENERAL.............................................................................................................421 DESCRIPTION.........................................................................................................423 STEERING WHEEL AND COLUMN ASSEMBLY..................................................................................424 Removal Of The Assembly Components..............................................................................424 Installation Of The Assembly Components.........................................................................428 POWER STEERING MOTOR AND PUMP...........................................................................................429 DESCRIPTION.........................................................................................................429 REMOVAL AND DISASSEMBLY, E1.25-3.00XL (E25-60XL), J2.00-3.00XL (J40-60XL), E2.00-3.20XM (E45-65XM)..................429 REMOVAL AND DISASSEMBLY, E3.50-5.50XL (E70-120XL, E70-120XL3).......................................................429 REMOVAL AND DISASSEMBLY, J2.00-3.20XM (J40-65XM)....................................................................430 REMOVAL AND DISASSEMBLY, A1.00-1.50XL (A20-30XL)...................................................................432 REMOVAL AND DISASSEMBLY, E1.50-2.00XMS (E25-40XMS)..................................................................433 ASSEMBLY AND INSTALLATION [All models with a verticle mount except the J2.00-3.20XM (J40-65M)]......................433 ASSEMBLY AND INSTALLATION, J2.00-3.20XM (J40-65XM)..................................................................434 ASSEMBLY AND INSTALLATION, E1.50-2.00XMS (E25-40XMS)................................................................436 REPAIRS, POWER STEERING PUMP........................................................................................437 Seal Replacement................................................................................................438 HYDRAULIC STEERING MOTOR................................................................................................438 DESCRIPTION.........................................................................................................438 REPAIRS, HYDRAULIC STEERING MOTOR...................................................................................439 Removal ........................................................................................................439 Disassembly.....................................................................................................439 Cleaning And Inspection.........................................................................................439 Assembly........................................................................................................440 Installation, Hydraulic Steering Motor..........................................................................441 CHECKS AND ADJUSTMENTS..................................................................................................441 AIR IN THE STEERING SYSTEM..........................................................................................441 CHECK STEERING PRESSURE.............................................................................................441 CHECK THE TENSION OF THE STEERING CHAIN (Units With MDU Only).......................................................442 CHECK OPTIONAL ENCODER AND ACTIVATOR CIRCUITS.......................................................................443 TROUBLESHOOTING.........................................................................................................445 INTRODUCTION............................................................................................................448 GENERAL.............................................................................................................448 DESCRIPTION.........................................................................................................448 REPAIRS.................................................................................................................448 REMOVAL.............................................................................................................448 DISASSEMBLY.........................................................................................................448 CLEANING............................................................................................................448 ASSEMBLY............................................................................................................448 Tilt Cylinders with O-Rings or Single Lip Seals.................................................................448 Tilt Cylinders for the XM and XMS Models........................................................................449 Tilt Cylinders for H700 800A and Early Model H700 920B..........................................................451 INSTALLATION........................................................................................................451 Tilt Cylinders Using Chevron Packing............................................................................452 CHECKS AND ADJUSTMENTS..................................................................................................454 CHECK THE TILT CYLINDERS FOR LEAKS..................................................................................454 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.............................................................454 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS................................................................455 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS...............................................................456 TROUBLESHOOTING.........................................................................................................458 VISTA® MASTS............................................................................................................459 GENERAL.............................................................................................................459 DESCRIPTION AND OPERATION...........................................................................................459 CARRIAGES...........................................................................................................459 TWO-STAGE MAST WITH LIMITED FREE-LIFT...............................................................................459 TWO-STAGE MAST WITH FULL FREE-LIFT MAST.............................................................................460 THREE-STAGE MAST WITH FULL FREE-LIFT................................................................................461 REPAIRS.................................................................................................................463 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)...............................................................463 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)...............................................................464 FORKS...............................................................................................................464 Forks, Removal And Installation.................................................................................464 CARRIAGE............................................................................................................466 Removal.........................................................................................................466 SIDE-SHIFT CARRIAGE (EARLIER DESIGNS)...............................................................................467 Disassembly, Side Shift Carriage................................................................................467 Assembly, Side Shift Carriage...................................................................................467 Installation....................................................................................................470 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGNS)........................................................................470 Removal.........................................................................................................470 Repairs.........................................................................................................471 Installation....................................................................................................472 WEIGHT OF MAST PARTS................................................................................................473 TWO-STAGE MAST WITH LIMITED FREE LIFT...............................................................................473 Removal.........................................................................................................473 Disassembly.....................................................................................................473 Cleaning and Inspection.........................................................................................475 Assembly........................................................................................................475 Installation....................................................................................................476 TWO-STAGE MAST WITH FULL FREE-LIFT..................................................................................476 Removal.........................................................................................................476 Disassembly.....................................................................................................476 Cleaning and Inspection.........................................................................................477 Assembly........................................................................................................477 Installation....................................................................................................478 THREE-STAGE MAST WITH FULL FREE LIFT................................................................................479 Removal.........................................................................................................479 Disassembly.....................................................................................................479 Cleaning and Inspection.........................................................................................479 Assembly........................................................................................................479 Installation....................................................................................................481 CHECKS AND ADJUSTMENTS..................................................................................................483 CHECK THE OPERATION OF THE MAST.....................................................................................483 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.........................................................................483 Lift System.....................................................................................................483 Tilt System.....................................................................................................483 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.....................................................484 LIFT CHAIN ADJUSTMENTS..........................................................................................484 MAST ADJUSTMENTS................................................................................................485 CARRIAGE ADJUSTMENT.............................................................................................486 TROUBLESHOOTING.................................................................................................487
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
