Hyster E-J1.25-1.75XL to V30ZMD Maintenance And Repair

Description

• Model List:
  • E-J1.25-1.75XL, E-J2.00-3.00XL, E2.00-3.20XM, N30XMH, N30XMH2, E2.00-3.20XM, V30ZMD

• 1. RM0285-(06-2010)-US-EN
• 1.1. Drive Axle, Speed Reducer, and Differential
• 1.2. Safety Precautions Maintenance and Repair
• 1.3. General
• 1.4. Description
• 1.5. Drive Axle, Speed Reducer, and Differential Repair
• 1.6. Drive Axle, Remove
• 1.7. Drive Axle, Disassemble
• 1.8. Speed Reducer and Differential, Disassemble
• 1.9. Inspect
• 1.10. Assemble
• 1.11. Speed Reducer and Differential, Assemble
• 1.12. Drive Axle, Assemble
• 1.13. Drive Axle Assembly, Install
• 1.14. Torque Specifications
• 1.15. Wheel Nuts
• 1.16. Axle Shaft Capscrews
• 1.17. Axle Hangers to Frame
• 1.18. Back Plate to Axle Mount Capscrews
• 1.19. Wheel Cylinder Capscrews
• 1.20. Ring Gear to Differential Case
• 1.21. Differential Case Halves
• 1.22. Bearing Cap Capscrews
• 1.23. Retainer Capscrews
• 1.24. Axle Housing to Differential Housing
• 1.25. Pinion Nut
• 1.26. Speed Reducer Housing to Differential Housing
• 1.27. Traction Motor to Transmission
• 1.28. Troubleshooting
• 1.29. Table 1. Adjustment of Shims for Pinion Assembly
• 1.30. Table 2. Ring and Pinion Tooth Contact Adjustment
• 2. RM0294-(03-2008)-UK-EN
• 2.1. General
• 2.2. Brush and Commutator Inspection
• 2.3. Brush Replacement
• 2.4. Stoning the Commutator
• 2.5. Motors Repair
• 2.6. Brush Alignment, Traction and Hydraulic Motors
• 2.7. Tests for Damaged Field and Armature
• 2.8. Troubleshooting
• 3. RM0294-(03-2008)-US-EN
• 3.1. General
• 3.2. Brush and Commutator Inspection
• 3.3. Brush Replacement
• 3.4. Stoning the Commutator
• 3.5. Motors Repair
• 3.6. Brush Alignment, Traction and Hydraulic Motors
• 3.7. Tests for Damaged Field and Armature
• 3.8. Troubleshooting
• 4. RM0485-(08-2003)-US-EN
• 4.1. Steering System for Electric Lift Trucks
• 4.2. Safety Precautions Maintenance and Repair
• 4.3. General
• 4.4. Description
• 4.5. Steering Wheel and Column Assembly Repair
• 4.6. Assembly Components, Remove
• 4.7. Assembly Components, Install
• 4.8. Power Steering Motor and Pump
• 4.9. Description
• 4.10. Remove and Disassemble, Models E1.25-3.00XL (E25-60XL), J2.00-3.
• 4.11. Remove and Disassemble, Models E3.50-5.50XL (E70-120XL, E70-120X
• 4.12. Remove and Disassemble, Models J2.00-3.20XM (J40-60XM, J40-60XM
• 4.13. Remove and Disassemble, Models A1.00-1.50XL (A20-30XL)
• 4.14. Remove and Disassemble, Models E1.50-2.00XMS (E25-40XMS, E25-40X
• 4.15. Assemble and Install – All models with a vertical mount except J
• 4.16. Assemble and Install, Models J2.00-3.20XM (J40-60XM, J40-60XM 2
• 4.17. Assemble and Install, Models E1.50-2.00XMS (E25-40XMS, E25-40XM
• 4.18. Power Steering Pump, Repair
• 4.19. Seal, Replace
• 4.20. Hydraulic Steering Motor
• 4.21. Description
• 4.22. Hydraulic Steering Motor Repairs
• 4.23. Disassemble
• 4.24. Clean and Inspect
• 4.25. Assemble
• 4.26. Install
• 4.27. Steering System Air Removal
• 4.28. Steering Pressure Check
• 4.29. Steering Chain Tension Check (Unit With MDU Only)
• 4.30. Optical Encoder and Activator Circuits Check
• 4.31. Troubleshooting
• 5. RM0512-(08-2003)-US-EN
• 5.1. Steering Housing and Control Unit
• 5.2. Safety Precautions Maintenance and Repair
• 5.3. General
• 5.4. Description
• 5.5. Operation
• 5.6. Steering Wheel and Column Assembly Repair
• 5.7. Steering Column Assembly, Remove
• 5.8. Steering Control Unit
• 5.9. Steering Column Assembly, Install
• 5.10. System Air Removal
• 5.11. Troubleshooting
• 6. RM0514-(01-2004)-US-EN
• 6.1. Instrument Cluster
• 6.2. Safety Precautions Maintenance and Repair
• 6.3. General
• 6.4. Description
• 6.5. Display Panels on Steering Column, Internal Combustion
• 6.6. Display Panels on Steering Column, Electric Lift Trucks
• 6.7. Standard Display Panel
• 6.8. Enhanced Display Panel
• 6.9. Curtis 1215 Display Panel
• 6.10. Description and Features
• 6.11. Operation
• 6.12. Cluster-Type Display Panel (Internal Combustion) Replacement
• 6.13. Remove and Disassemble
• 6.14. Assemble and Install
• 6.15. Cluster Display Panel (Electric Lift Truck) Replacement
• 6.16. Display Panel Assembly, Replace
• 6.17. LED Indicators
• 6.18. Battery Indicators
• 6.19. Digital Display (Enhanced Display Panel Only)
• 6.20. Status Code or Performance Level Switches and LED indicators (En
• 6.21. Standard Display Panel Parts, Replace
• 6.22. Enhanced Display Panel Parts, Replace
• 6.23. Curtis 1215 Display Panel Replacement
• 6.24. Install
• 6.25. Table 1. Instrument Cluster, Internal Combustion
• 7. RM0521-(03-2006)-UK-EN
• 7.1. Safety Precautions Maintenance and Repair
• 7.2. General
• 7.3. Description and Operation
• 7.4. Carriages
• 7.5. Mast Mounts
• 7.6. Two-Stage Mast, Limited Free-Lift (LFL)
• 7.7. Description and Operation
• 7.8. Two-Stage Mast, Full Free-Lift (FFL)
• 7.9. Description and Operation
• 7.10. Three-Stage Mast, Full Free-Lift (FFL)
• 7.11. Description and Operation
• 7.12. Four-Stage Mast
• 7.13. Description and Operation
• 7.14. Cylinder Cushion During Lifting Sequence
• 7.15. Cylinder Cushion During Lowering Sequence
• 8. RM0521-(03-2006)-US-EN
• 8.1. Safety Precautions Maintenance and Repair
• 8.2. General
• 8.3. Description and Operation
• 8.4. Carriages
• 8.5. Mast Mounts
• 8.6. Two-Stage Mast, Limited Free-Lift (LFL)
• 8.7. Description and Operation
• 8.8. Two-Stage Mast, Full Free-Lift (FFL)
• 8.9. Description and Operation
• 8.10. Three-Stage Mast, Full Free-Lift (FFL)
• 8.11. Description and Operation
• 8.12. Four-Stage Mast
• 8.13. Description and Operation
• 8.14. Cylinder Cushion During Lifting Sequence
• 8.15. Cylinder Cushion During Lowering Sequence
• 9. RM0522-(07-2010)-US-EN
• 9.1. Mast Repairs
• 9.2. Safety Precautions Maintenance and Repair
• 9.3. General
• 9.4. Safety Procedures When Working Near Mast
• 9.5. Fork Repair
• 9.6. Install
• 9.7. Carriages Repair
• 9.8. Standard Carriage, Remove
• 9.9. Hang-On Sideshift Carriage, Remove
• 9.10. Standard Carriage and Hang-On Sideshift Carriage, Repair
• 9.11. Standard Carriage, Install
• 9.12. Hang-On Sideshift Carriage, Install
• 9.13. Integral Sideshift Carriage
• 9.14. Clean and Inspect
• 9.15. Install
• 9.16. Mast Repair
• 9.17. Two-Stage LFL and Two-Stage FFL Masts, Disassemble
• 9.18. Three-Stage FFL Mast
• 9.19. Disassemble
• 9.20. Mast and Chains, Clean and Inspect
• 9.21. Two-Stage LFL and Two-Stage FFL Mast, Assemble
• 9.22. Three-Stage FFL Mast, Assemble
• 9.23. Install
• 9.24. Lift Cylinders Repair
• 9.25. Main Lift Cylinders, Remove
• 9.26. Free-Lift Cylinder, Remove
• 9.27. Cylinders, Disassemble
• 9.28. Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
• 9.29. Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
• 9.30. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
• 9.31. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
• 9.32. Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
• 9.33. Clean and Inspect
• 9.34. Cylinders, Assemble
• 9.35. Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
• 9.36. Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
• 9.37. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
• 9.38. Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
• 9.39. Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
• 9.40. Main Lift Cylinders, Install
• 9.41. Free-Lift Cylinder, Install
• 9.42. Header Hose Arrangements
• 9.43. Two-Stage LFL Mast, New Hose Install
• 9.44. Two-Stage LFL Mast, Adjust Hoses After Installation
• 9.45. Two-Stage FFL Mast, New Hose Install
• 9.46. Two-Stage FFL Mast, Adjust Hoses After Installation
• 9.47. Three-Stage FFL Mast, New Hose Install
• 9.48. Three-Stage FFL Mast, Adjust Hoses After Installation
• 9.49. Header Hose Arrangement
• 9.50. Two-Stage LFL Mast, New Hose Install
• 9.51. Two-Stage LFL Mast, Adjust Hoses After Installation
• 9.52. Two-Stage FFL Mast, New Hose Install
• 9.53. Two-Stage FFL Mast, Adjust Hoses After Installation
• 9.54. Three-Stage FFL Mast, New Hose Install
• 9.55. Three-Stage FFL Mast, Adjust Hoses After Install
• 9.56. Lift and Tilt System Leak Check
• 9.57. Lift Cylinders Leak Check
• 9.58. Tilt Cylinders Leak Check
• 9.59. Tilt Cylinders Adjustment
• 9.60. Lift Chains Adjustment
• 9.61. Mast Adjustment
• 9.62. Carriage Adjustment
• 9.63. Troubleshooting
• 9.64. Table 1. Hook-Type Carriage Chain Adjustment
• 9.65. Table 2. Pin-Type Carriage Chain Adjustment
• 10. RM0552-(01-2004)-US-EN
• 10.1. Periodic Maintenance
• 10.2. Safety Precautions Maintenance and Repair
• 10.3. General
• 10.4. Serial Number Data
• 10.5. How to Move Disabled Lift Truck
• 10.6. How to Tow Lift Truck
• 10.7. How to Put Lift Truck on Blocks
• 10.8. How to Raise Drive Tires
• 10.9. How to Raise Steering Tires
• 10.10. Maintenance Schedule
• 10.11. Maintenance Procedures Every 8 Hours or Daily
• 10.12. How to Make Checks With Key OFF
• 10.13. Tires and Wheels
• 10.14. Forks, Mast, and Lift Chains, Inspect
• 10.15. Safety Labels
• 10.16. Steering Column Latch
• 10.17. Operator Restraint System
• 10.18. Battery Restraint System E1.50-3.20XM, E2.00XMS (E25-65XM, E25-6
• 10.19. Battery Restraint System J2.00-3.20XM (J40-60XM and J40-60XM 2 )
• 10.20. Battery
• 10.21. Hydraulic System
• 10.22. How to Make Checks With Key ON
• 10.23. Gauges, Horn, and Fuses
• 10.24. Steering System
• 10.25. Service Brakes
• 10.26. Parking Brake
• 10.27. Control Levers and Pedals
• 10.28. Direction and Speed Control Pedals
• 10.29. Lift System Operation
• 10.30. Maintenance Procedures Every 250 Hours or 6 Weeks
• 10.31. Steering Tie Rods
• 10.32. Steering King Pins, Trucks Only
• 10.33. Maintenance Procedures Every 500 Hours or 3 Months
• 10.34. Hydraulic Tank Breather
• 10.35. Differential and Speed Reducer
• 10.36. Wheel Nut Torques
• 10.37. Steering Axle Spindles
• 10.38. Steering Tie Rods
• 10.39. Lift Chains
• 10.40. Wear Check
• 10.41. Brake Fluid
• 10.42. Other Lubrication
• 10.43. Seat Brake, Models E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM
• 10.44. Electrical Inspection
• 10.45. Contactors
• 10.46. Motor Brushes
• 10.47. Motor Brushes, General
• 10.48. Maintenance Procedures Every 1000 Hours or 6 Months
• 10.49. Lift Chains
• 10.50. Check Upper and Lower Bearings, Integral Sideshift Carriage
• 10.51. Maintenance Procedures Every 2000 Hours or Yearly
• 10.52. Hydraulic System
• 10.53. Change Filter for Hydraulic Oil
• 10.54. Change Hydraulic Oil
• 10.55. Differential and Speed Reducer
• 10.56. Service Brakes
• 10.57. Contactors
• 10.58. Wheel Bearings
• 10.59. Steer Wheels, Lubrication
• 10.60. Drive Wheels, Lubrication
• 10.61. Lift Chains
• 10.62. Replace Upper and Lower Bearings, Integral Sideshift Carriage
• 10.63. Steering Axle
• 10.64. King Pins and Rod Ends (Steering Cylinders)
• 10.65. Other Lubrication
• 10.66. Battery Maintenance
• 10.67. How to Charge Battery
• 10.68. How to Change Battery
• 10.69. General
• 10.70. Change Battery, E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM 2
• 10.71. Change J2.00-3.20XM (J40-60XM and J40-60XM 2 ) Battery
• 10.72. Lift and Tilt System Leak Check
• 10.73. Lift Cylinders Leak Check
• 10.74. Tilt Cylinders Leak Check
• 10.75. Safety Procedures When Working Near Mast
• 10.76. Lift Chain Adjustments
• 10.77. PMT Circuit Check
• 10.78. Welding Repairs
• 10.79. Overhead Guard Changes
• 10.80. Wheels and Tire Maintenance
• 10.81. Tires and Wheels, E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM
• 10.82. Remove Wheels From Lift Truck
• 10.83. Remove and Install Tire on Wheel
• 10.84. Pneumatic Tires and Wheels J2.00-3.20XM (J40-60XM and J40-60XM 2
• 10.85. Remove Wheels From Lift Truck
• 10.86. Remove Wheel From Pneumatic Tire
• 10.87. Install Wheel in Pneumatic Tire
• 10.88. Install Three- or Four-Piece Wheel in Pneumatic Tire
• 10.89. Add Air to Tires
• 10.90. Wheels, Install
• 10.91. Solid Rubber Tires on Pneumatic Wheels
• 10.92. Remove Wheels From Lift Truck
• 10.93. Remove Solid Rubber Tire From Pneumatic Wheel
• 10.94. Install Solid Rubber Tire on Pneumatic Wheel
• 10.95. Wheels, Install
• 10.96. Solid Rubber Tire, Change
• 10.97. Remove and Install Tire on Wheel
• 10.98. Remove Wheel From Tire
• 10.99. Install Wheel in Tire
• 10.100. SIT Tire, Change
• 10.101. Remove SIT Solid Tire From Wheel
• 10.102. Install SIT Solid Tire on Wheel
• 10.103. Adhesives and Sealants
• 10.104. Table 1. Maintenance Schedule
• 11. RM0551-(08-2003)-US-EN
• 11.1. Electrical Diagrams
• 11.2. Safety Precautions Maintenance and Repair
• 12. RM0557-(08-2003)-US-EN
• 12.1. EV-100ZX SCR Motor Controller
• 12.2. Safety Precautions Maintenance and Repair
• 12.3. General
• 12.4. Model Number Data For EV-100ZX Controller
• 12.5. Register Parameters
• 12.6. General
• 12.7. Function Numbers
• 12.8. Control Card, Checks and Adjustments
• 12.9. Handset