Hyster DC Motor All Electric Lift Truck Maintenance And Repair

Description

• Model List:
  • DC Motor All Electric Lift Truck

• 1. RM0294-(03-2008)-US-EN
• 1.1. General
• 1.2. Brush and Commutator Inspection
• 1.3. Brush Replacement
• 1.4. Stoning the Commutator
• 1.5. Motors Repair
• 1.6. Brush Alignment, Traction and Hydraulic Motors
• 1.7. Tests for Damaged Field and Armature
• 1.8. Troubleshooting
• 2. RM0316-(08-2006)-US-EN
• 2.1. Steering Axle
• 2.2. Safety Precautions Maintenance and Repair
• 2.3. General
• 2.4. Description
• 2.5. Steering Axle Assembly Repair
• 2.6. Install
• 2.7. Wheels and Hubs Repair
• 2.8. Remove and Disassemble
• 2.9. Assemble and Install
• 2.10. Spindles, Bearings, and Tie Rods Repair
• 2.11. Install
• 2.12. Steering Cylinder Repair
• 2.13. Remove and Disassemble
• 2.14. Clean and Inspect
• 2.15. Assemble and Install
• 2.16. Torque Specifications
• 2.17. Troubleshooting
• 3. RM0485-(08-2003)-US-EN
• 3.1. Steering System for Electric Lift Trucks
• 3.2. Safety Precautions Maintenance and Repair
• 3.3. General
• 3.4. Description
• 3.5. Steering Wheel and Column Assembly Repair
• 3.6. Assembly Components, Remove
• 3.7. Assembly Components, Install
• 3.8. Power Steering Motor and Pump
• 3.9. Description
• 3.10. Remove and Disassemble, Models E1.25-3.00XL (E25-60XL), J2.00-3.
• 3.11. Remove and Disassemble, Models E3.50-5.50XL (E70-120XL, E70-120X
• 3.12. Remove and Disassemble, Models J2.00-3.20XM (J40-60XM, J40-60XM
• 3.13. Remove and Disassemble, Models A1.00-1.50XL (A20-30XL)
• 3.14. Remove and Disassemble, Models E1.50-2.00XMS (E25-40XMS, E25-40X
• 3.15. Assemble and Install – All models with a vertical mount except J
• 3.16. Assemble and Install, Models J2.00-3.20XM (J40-60XM, J40-60XM 2
• 3.17. Assemble and Install, Models E1.50-2.00XMS (E25-40XMS, E25-40XM
• 3.18. Power Steering Pump, Repair
• 3.19. Seal, Replace
• 3.20. Hydraulic Steering Motor
• 3.21. Description
• 3.22. Hydraulic Steering Motor Repairs
• 3.23. Disassemble
• 3.24. Clean and Inspect
• 3.25. Assemble
• 3.26. Install
• 3.27. Steering System Air Removal
• 3.28. Steering Pressure Check
• 3.29. Steering Chain Tension Check (Unit With MDU Only)
• 3.30. Optical Encoder and Activator Circuits Check
• 3.31. Troubleshooting
• 4. RM0512-(08-2003)-US-EN
• 4.1. Steering Housing and Control Unit
• 4.2. Safety Precautions Maintenance and Repair
• 4.3. General
• 4.4. Description
• 4.5. Operation
• 4.6. Steering Wheel and Column Assembly Repair
• 4.7. Steering Column Assembly, Remove
• 4.8. Steering Control Unit
• 4.9. Steering Column Assembly, Install
• 4.10. System Air Removal
• 4.11. Troubleshooting
• 5. RM0514-(01-2004)-US-EN
• 5.1. Instrument Cluster
• 5.2. Safety Precautions Maintenance and Repair
• 5.3. General
• 5.4. Description
• 5.5. Display Panels on Steering Column, Internal Combustion
• 5.6. Display Panels on Steering Column, Electric Lift Trucks
• 5.7. Standard Display Panel
• 5.8. Enhanced Display Panel
• 5.9. Curtis 1215 Display Panel
• 5.10. Description and Features
• 5.11. Operation
• 5.12. Cluster-Type Display Panel (Internal Combustion) Replacement
• 5.13. Remove and Disassemble
• 5.14. Assemble and Install
• 5.15. Cluster Display Panel (Electric Lift Truck) Replacement
• 5.16. Display Panel Assembly, Replace
• 5.17. LED Indicators
• 5.18. Battery Indicators
• 5.19. Digital Display (Enhanced Display Panel Only)
• 5.20. Status Code or Performance Level Switches and LED indicators (En
• 5.21. Standard Display Panel Parts, Replace
• 5.22. Enhanced Display Panel Parts, Replace
• 5.23. Curtis 1215 Display Panel Replacement
• 5.24. Install
• 5.25. Table 1. Instrument Cluster, Internal Combustion
• 6. RM0521-(03-2006)-US-EN
• 6.1. Safety Precautions Maintenance and Repair
• 6.2. General
• 6.3. Description and Operation
• 6.4. Carriages
• 6.5. Mast Mounts
• 6.6. Two-Stage Mast, Limited Free-Lift (LFL)
• 6.7. Description and Operation
• 6.8. Two-Stage Mast, Full Free-Lift (FFL)
• 6.9. Description and Operation
• 6.10. Three-Stage Mast, Full Free-Lift (FFL)
• 6.11. Description and Operation
• 6.12. Four-Stage Mast
• 6.13. Description and Operation
• 6.14. Cylinder Cushion During Lifting Sequence
• 6.15. Cylinder Cushion During Lowering Sequence
• 7. RM0522-(07-2010)-US-EN
• 7.1. Mast Repairs
• 7.2. Safety Precautions Maintenance and Repair
• 7.3. General
• 7.4. Safety Procedures When Working Near Mast
• 7.5. Fork Repair
• 7.6. Install
• 7.7. Carriages Repair
• 7.8. Standard Carriage, Remove
• 7.9. Hang-On Sideshift Carriage, Remove
• 7.10. Standard Carriage and Hang-On Sideshift Carriage, Repair
• 7.11. Standard Carriage, Install
• 7.12. Hang-On Sideshift Carriage, Install
• 7.13. Integral Sideshift Carriage
• 7.14. Clean and Inspect
• 7.15. Install
• 7.16. Mast Repair
• 7.17. Two-Stage LFL and Two-Stage FFL Masts, Disassemble
• 7.18. Three-Stage FFL Mast
• 7.19. Disassemble
• 7.20. Mast and Chains, Clean and Inspect
• 7.21. Two-Stage LFL and Two-Stage FFL Mast, Assemble
• 7.22. Three-Stage FFL Mast, Assemble
• 7.23. Install
• 7.24. Lift Cylinders Repair
• 7.25. Main Lift Cylinders, Remove
• 7.26. Free-Lift Cylinder, Remove
• 7.27. Cylinders, Disassemble
• 7.28. Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
• 7.29. Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
• 7.30. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
• 7.31. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
• 7.32. Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
• 7.33. Clean and Inspect
• 7.34. Cylinders, Assemble
• 7.35. Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
• 7.36. Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
• 7.37. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
• 7.38. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
• 7.39. Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
• 7.40. Main Lift Cylinders, Install
• 7.41. Free-Lift Cylinder, Install
• 7.42. Header Hose Arrangements
• 7.43. Two-Stage LFL Mast, New Hose Install
• 7.44. Two-Stage LFL Mast, Adjust Hoses After Installation
• 7.45. Two-Stage FFL Mast, New Hose Install
• 7.46. Two-Stage FFL Mast, Adjust Hoses After Installation
• 7.47. Three-Stage FFL Mast, New Hose Install
• 7.48. Three-Stage FFL Mast, Adjust Hoses After Installation
• 7.49. Header Hose Arrangement
• 7.50. Two-Stage LFL Mast, New Hose Install
• 7.51. Two-Stage LFL Mast, Adjust Hoses After Installation
• 7.52. Two-Stage FFL Mast, New Hose Install
• 7.53. Two-Stage FFL Mast, Adjust Hoses After Installation
• 7.54. Three-Stage FFL Mast, New Hose Install
• 7.55. Three-Stage FFL Mast, Adjust Hoses After Install
• 7.56. Lift and Tilt System Leak Check
• 7.57. Lift Cylinders Leak Check
• 7.58. Tilt Cylinders Leak Check
• 7.59. Tilt Cylinders Adjustment
• 7.60. Lift Chains Adjustment
• 7.61. Mast Adjustment
• 7.62. Carriage Adjustment
• 7.63. Troubleshooting
• 7.64. Table 1. Hook-Type Carriage Chain Adjustment
• 7.65. Table 2. Pin-Type Carriage Chain Adjustment
• 8. RM0552-(01-2004)-US-EN
• 8.1. Periodic Maintenance
• 8.2. Safety Precautions Maintenance and Repair
• 8.3. General
• 8.4. Serial Number Data
• 8.5. How to Move Disabled Lift Truck
• 8.6. How to Tow Lift Truck
• 8.7. How to Put Lift Truck on Blocks
• 8.8. How to Raise Drive Tires
• 8.9. How to Raise Steering Tires
• 8.10. Maintenance Schedule
• 8.11. Maintenance Procedures Every 8 Hours or Daily
• 8.12. How to Make Checks With Key OFF
• 8.13. Tires and Wheels
• 8.14. Forks, Mast, and Lift Chains, Inspect
• 8.15. Safety Labels
• 8.16. Steering Column Latch
• 8.17. Operator Restraint System
• 8.18. Battery Restraint System E1.50-3.20XM, E2.00XMS (E25-65XM, E25-6
• 8.19. Battery Restraint System J2.00-3.20XM (J40-60XM and J40-60XM 2 )
• 8.20. Battery
• 8.21. Hydraulic System
• 8.22. How to Make Checks With Key ON
• 8.23. Gauges, Horn, and Fuses
• 8.24. Steering System
• 8.25. Service Brakes
• 8.26. Parking Brake
• 8.27. Control Levers and Pedals
• 8.28. Direction and Speed Control Pedals
• 8.29. Lift System Operation
• 8.30. Maintenance Procedures Every 250 Hours or 6 Weeks
• 8.31. Steering Tie Rods
• 8.32. Steering King Pins, Trucks Only
• 8.33. Maintenance Procedures Every 500 Hours or 3 Months
• 8.34. Hydraulic Tank Breather
• 8.35. Differential and Speed Reducer
• 8.36. Wheel Nut Torques
• 8.37. Steering Axle Spindles
• 8.38. Steering Tie Rods
• 8.39. Lift Chains
• 8.40. Wear Check
• 8.41. Brake Fluid
• 8.42. Other Lubrication
• 8.43. Seat Brake, Models E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM
• 8.44. Electrical Inspection
• 8.45. Contactors
• 8.46. Motor Brushes
• 8.47. Motor Brushes, General
• 8.48. Maintenance Procedures Every 1000 Hours or 6 Months
• 8.49. Lift Chains
• 8.50. Check Upper and Lower Bearings, Integral Sideshift Carriage
• 8.51. Maintenance Procedures Every 2000 Hours or Yearly
• 8.52. Hydraulic System
• 8.53. Change Filter for Hydraulic Oil
• 8.54. Change Hydraulic Oil
• 8.55. Differential and Speed Reducer
• 8.56. Service Brakes
• 8.57. Contactors
• 8.58. Wheel Bearings
• 8.59. Steer Wheels, Lubrication
• 8.60. Drive Wheels, Lubrication
• 8.61. Lift Chains
• 8.62. Replace Upper and Lower Bearings, Integral Sideshift Carriage
• 8.63. Steering Axle
• 8.64. King Pins and Rod Ends (Steering Cylinders)
• 8.65. Other Lubrication
• 8.66. Battery Maintenance
• 8.67. How to Charge Battery
• 8.68. How to Change Battery
• 8.69. General
• 8.70. Change Battery, E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM 2
• 8.71. Change J2.00-3.20XM (J40-60XM and J40-60XM 2 ) Battery
• 8.72. Lift and Tilt System Leak Check
• 8.73. Lift Cylinders Leak Check
• 8.74. Tilt Cylinders Leak Check
• 8.75. Safety Procedures When Working Near Mast
• 8.76. Lift Chain Adjustments
• 8.77. PMT Circuit Check
• 8.78. Welding Repairs
• 8.79. Overhead Guard Changes
• 8.80. Wheels and Tire Maintenance
• 8.81. Tires and Wheels, E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM
• 8.82. Remove Wheels From Lift Truck
• 8.83. Remove and Install Tire on Wheel
• 8.84. Pneumatic Tires and Wheels J2.00-3.20XM (J40-60XM and J40-60XM 2
• 8.85. Remove Wheels From Lift Truck
• 8.86. Remove Wheel From Pneumatic Tire
• 8.87. Install Wheel in Pneumatic Tire
• 8.88. Install Three- or Four-Piece Wheel in Pneumatic Tire
• 8.89. Add Air to Tires
• 8.90. Wheels, Install
• 8.91. Solid Rubber Tires on Pneumatic Wheels
• 8.92. Remove Wheels From Lift Truck
• 8.93. Remove Solid Rubber Tire From Pneumatic Wheel
• 8.94. Install Solid Rubber Tire on Pneumatic Wheel
• 8.95. Wheels, Install
• 8.96. Solid Rubber Tire, Change
• 8.97. Remove and Install Tire on Wheel
• 8.98. Remove Wheel From Tire
• 8.99. Install Wheel in Tire
• 8.100. SIT Tire, Change
• 8.101. Remove SIT Solid Tire From Wheel
• 8.102. Install SIT Solid Tire on Wheel
• 8.103. Adhesives and Sealants
• 8.104. Table 1. Maintenance Schedule
• 9. RM0551-(08-2003)-US-EN
• 9.1. Electrical Diagrams
• 9.2. Safety Precautions Maintenance and Repair
• 10. RM0557-(08-2003)-US-EN
• 10.1. EV-100ZX SCR Motor Controller
• 10.2. Safety Precautions Maintenance and Repair
• 10.3. General
• 10.4. Model Number Data For EV-100ZX Controller
• 10.5. Register Parameters
• 10.6. General
• 10.7. Function Numbers
• 10.8. Control Card, Checks and Adjustments
• 10.9. Handset
• 10.10. How to Check and Adjust Registers
• 10.11. How to Scroll through Fault Codes and Clear Them
• 10.12. Checks and Adjustments on Workbench
• 10.13. When Handset Is Connected to Control Card Installed In Lift Truc
• 10.14. Function Numbers 1 through 15
• 10.15. Function Numbers 16 through 30
• 10.16. Function Numbers 48 through 62
• 10.17. Control Cards
• 10.18. Function Number Descriptions
• 10.19. Traction Control Cards (Label Letters – ZH and ZY)
• 10.20. Function Number 1 STORED STATUS CODE
• 10.21. Function Number 2 CREEP SPEED
• 10.22. Function Number 3 CONTROLLED ACCELERATION AND 1A TIME
• 10.23. Function Number 4 CURRENT LIMIT
• 10.24. Function Number 5 PLUGGING DISTANCE (CURRENT)
• 10.25. Function Number 6 1A DROP OUT CURRENT
• 10.26. Function Number 7 FIELD WEAKENING PICK UP
• 10.27. Function Number 8 FIELD WEAKENING DROP OUT
• 10.28. Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT
• 10.29. Function Number 10 REGENERATIVE BRAKING START
• 10.30. Function Number 13 SPEED LIMIT 3 (SL3)
• 10.31. Function Number 14 INTERNAL RESISTANCE COMPENSATION
• 10.32. Function Number 15 BATTERY VOLTS
• 10.33. Function Numbers GREATER THAN 15
• 10.34. Function Number 16 PEDAL POSITION PLUG
• 10.35. Function Number 17 CARD TYPE SELECTION
• 10.36. Function Number 18 STEERING PUMP TIME DELAY
• 10.37. Function Number 19 MAINTENANCE ALERT (Tens/Units)
• 10.38. Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)
• 10.39. Function Number 21 MAINTENANCE SPEED LIMIT
• 10.40. Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS
• 10.41. Function Number 29 HOURMETER (Tens/Units)