Hyster Industrial Battery All Electric Lift Truck Maintenance And Repair

Description

• Model List:
  • Industrial Battery All Electric Lift Truck

• 1. RM0001-(01-2016)-UK-EN
• 1.1. General
• 1.2. Lead-Acid Batteries
• 1.3. Specific Gravity
• 1.4. Chemical Reaction in a Cell
• 1.5. Electrical Terms
• 1.6. Battery Selection
• 1.7. Battery Voltage
• 1.8. Battery as a Counterweight
• 1.9. Battery Ratings
• 1.10. Battery Maintenance
• 1.11. Troubleshooting
• 2. RM0231-(01-2016)-UK-EN
• 2.1. General
• 3. RM1128-(01-2016)-UK-EN
• 3.1. General
• 3.2. Deutsch Crimping Tool
• 3.3. Deutsch Connectors
• 3.4. Metri-Pack Connectors
• 3.5. Micro-Pack Connectors
• 3.6. Weather-Pack Connectors
• 3.7. AMPSEAL Crimping Tools
• 3.8. AMPSEAL Connector Assemblies
• 3.9. AMP Superseal 1.5 Crimping Tools
• 3.10. AMP Superseal 1.5 Connector Assemblies
• 3.11. AMP Fastin-Faston Hand Tools
• 3.12. AMP Fastin-Faston Receptacles and Housings
• 3.13. Wire Repair
• 3.14. Twisted/Shielded Cable and Leads Repair
• 3.15. Special Tools
• 4. RM1342-(01-2016)-UK-EN
• 4.1. General
• 4.2. Covers and Floor Plates
• 4.3. Overhead Guard Replacement
• 4.4. Battery and Operator Restraint System Repair
• 4.5. Hood and Seat Assembly Replacement
• 4.6. Hood and Seat Assembly Replacement for Lift Truck Model J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)
• 4.7. Master Cylinder Repair and Adjustment for 1.5-3.5T Cushion and 2.2-5.5T Pneumatic Lift Trucks
• 4.8. Master Cylinder Repair and Adjustment for 4.0-5.5T Cushion Lift Trucks
• 4.9. Brake Pedal Components
• 4.10. Brake System Air Removal
• 4.11. Counterweight Replacement for Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)
• 4.12. Counterweight Replacement for Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)
• 4.13. Counterweight Replacement for Lift Truck Models E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
• 4.14. Traction Motor Replacement for Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)
• 4.15. Traction Motor Replacement for Lift Truck Models J2.2-3.5XN (J45-70XN) (A276) and J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)
• 4.16. Traction Motor Replacement for Lift Truck Models E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
• 4.17. Hydraulic Tank Inspection
• 4.18. Painting Instructions
• 4.19. Safety Label Replacement
• 4.20. Battery Specifications
• 4.21. Torque Specifications for Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)
• 4.22. Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
• 4.23. Torque Specifications for Lift Truck J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)
• 4.24. Torque Specifications for Lift Truck E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
• 5. RM1366-(09-2013)-UK-EN
• 5.1. Drive Axle, Speed Reducer, and Differential
• 5.2. Safety Precautions Maintenance and Repair
• 5.3. General
• 5.4. Drive Axle Repair
• 5.5. Disassemble
• 5.6. Inspect
• 5.7. Assemble
• 5.8. Install
• 5.9. Differential Repair
• 5.10. Differential Assembly From Center Section
• 5.11. Drive Pinion, Pinion Gear, and Bearings From Center Section
• 5.12. Disassemble
• 5.13. Differential Assembly, Lift Truck Models E2.2-3.5XN (E45-70XN) (
• 5.14. Differential Assembly, Lift Truck Models E1.6-2.0XN (E30-40XN) (
• 5.15. Clean and Inspect
• 5.16. Assemble
• 5.17. Differential Assembly, Lift Truck Models E2.2-3.5XN (E45-70XN) (
• 5.18. Differential Assembly, Lift Truck Models E1.6-2.0XN (E30-40XN) (
• 5.19. Install
• 5.20. Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)
• 5.21. Drive Pinion, Pinion Gear, and Bearings Into Center Section
• 5.22. Differential Assembly Into Center Section
• 5.23. Ring Gear Backlash, Adjust
• 5.24. Ring Gear, Runout Check
• 5.25. Gear Set, Tooth Contact Pattern Check
• 5.26. Torque Specifications
• 5.27. Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)
• 5.28. Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)
• 5.29. Table 1. Pinion Variation Numbers Examples
• 5.30. Table 2. Ring and Pinion Tooth Contact Adjustment
• 5.31. Table 3. Correct Tooth Contact
• 5.32. Table 4. Incorrect Tooth Contact
• 6. RM1360-(01-2016)-UK-EN
• 6.1. General
• 6.2. Steering Axle Assembly Repair
• 6.3. Tie Rod Replacement
• 6.4. Spindle Repair
• 6.5. Steering Cylinder Repair
• 7. RM1363-(09-2014)-UK-EN
• 8. RM1359-(03-2012)-UK-EN
• 8.1. Brake System
• 8.2. Safety Precautions Maintenance and Repair
• 8.3. General
• 8.4. Dry Brake System
• 8.5. Service Brakes Repair (Dry Brake)
• 8.6. Remove and Disassemble
• 8.7. Inspect
• 8.8. Assemble and Install
• 8.9. Parking Brake Repair
• 8.10. Remove and Disassemble
• 8.11. Inspect
• 8.12. Assemble and Install
• 8.13. Master Cylinder Repair
• 8.14. Disassemble
• 8.15. Inspect
• 8.16. Assemble
• 8.17. Bench Bleed Master Cylinder
• 8.18. Install and Adjust
• 8.19. Brake Pedal Components
• 8.20. Disassemble
• 8.21. Inspect
• 8.22. Assemble
• 8.23. Install
• 8.24. Automatic Park Brake
• 8.25. General
• 8.26. Manual Release Handle
• 8.27. Automatic Park Brake Assembly
• 8.28. Automatic Park Brake Module
• 8.29. Disassemble
• 8.30. Clean and Inspect
• 8.31. Assemble
• 8.32. Install
• 8.33. Automatic Park Brake Module
• 8.34. Manual Release Handle
• 8.35. Automatic Park Brake Assembly
• 8.36. Adjustments
• 8.37. Service Brakes Adjustment (Dry Brake)
• 8.38. Brake Adjust
• 8.39. Parking Brake Adjustment
• 8.40. Brake System Air Removal
• 8.41. Brake System Air Removal
• 8.42. Using Pressure Bleed System
• 8.43. Using Brake Pedal Pressure
• 8.44. Brake Pedal Adjustment
• 8.45. Brake Pedal Adjustment
• 8.46. Master Cylinder Adjustment
• 8.47. Adjust Push Rod
• 8.48. Parking Brake Not Applied Switch Test
• 8.49. Torque Specifications
• 9. RM1367-(01-2016)-UK-EN
• 9.1. General
• 9.2. Hydraulic Pump and Motor
• 9.3. Hydraulic Tank
• 9.4. Steer Accumulator Replacement
• 9.5. Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268)
• 9.6. Specifications for Lift Truck E1.6-2.0XN (E30-40XN) (A269)
• 9.7. Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
• 9.8. Specifications for Lift Truck J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)
• 9.9. Specifications for Lift Truck E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
• 9.10. Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268)
• 9.11. Torque Specifications for Lift Truck E1.6-2.0XN (E30-40XN) (A269)
• 9.12. Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276)
• 9.13. Torque Specifications for Lift Truck J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)
• 9.14. Torque Specifications for Lift Truck E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
• 10. RM1334-(09-2014)-UK-EN
• 11. RM1382-(11-2015)-UK-EN
• 11.1. Safety Procedures When Working Near Mast
• 11.2. General
• 11.3. Description
• 11.4. Tilt Cylinder Repair for 1.0-2.0T Trucks
• 11.5. Tilt Cylinder Repair for 2.0-5.5T Trucks
• 11.6. Lift Cylinder Repair for Lift Truck Model J1.5XNT (K160)
• 11.7. Lift Cylinder Repair for 1.5-2.0T Trucks
• 11.8. Lift Cylinder Repair for 2.0-3.5T Trucks
• 11.9. Lift Cylinder Repair for 4.0-5.5T Trucks
• 11.10. Free Lift Cylinder Repair for Lift Truck Model J1.5XNT (K160)
• 11.11. Free Lift Cylinder Repair for 1.5-2.0T Trucks
• 11.12. Free-Lift Cylinder Repair for 2.0-3.5T Trucks
• 11.13. Free-Lift Cylinder Repair for 4.0-5.5T Trucks
• 11.14. Sideshift Cylinder Repair for 1.5-3.5T Trucks
• 11.15. Sideshift Cylinder Repair for 4.0-5.5T Trucks
• 11.16. Fork Positioner Cylinder Repair
• 11.17. Lift Cylinder Leak Check
• 11.18. Seal Kit Installation
• 11.19. Torque Specifications for Lift Truck Model J1.5XNT (K160)
• 11.20. Torque Specifications for Lift Truck Models J1.6-2.0XNT (J30-40XNT) (K160), J1.6-2.0XN (J30-40XN) (A935), E30-40HSD2 (B219), and E30-40HSD3 (C219)
• 11.21. Torque Specifications for Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and J2.2-3.5XN (J45-70XN) (A276)
• 11.22. Torque Specifications for Lift Truck Model J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)
• 11.23. Torque Specifications for Lift Truck Model E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
• 12. RM1335-(09-2014)-UK-EN
• 13. RM1336-(09-2014)-UK-EN
• 14. RM1369-(01-2016)-UK-EN
• 14.1. General
• 14.2. Display Panel and Key or Keyless Switch Replacement
• 14.3. Electronic and Manual Hydraulic Controls
• 14.4. Sensors and Switches
• 14.5. Motor Controllers Replacement
• 14.6. Vehicle System Manager
• 14.7. Fuses and Relays
• 14.8. Backup Alarm
• 14.9. Battery Connection
• 14.10. Cab Heater
• 15. RM1338-(11-2015)-UK-EN
• 15.1. General
• 15.2. Safety Procedures When Working Near Mast
• 15.3. Fork Replacement
• 15.4. Carriages Repair
• 15.5. Two-Stage Mast With Limited Free-Lift Repair
• 15.6. Two-Stage Mast With Full Free-Lift Repair
• 15.7. Three-Stage Mast With Full Free-Lift Repair
• 15.8. Four-Stage Mast With Full Free-Lift Repair
• 15.9. Lift Chains Adjustment
• 15.10. Carriage Adjustments
• 15.11. Mast Adjustments
• 16. RM1374-(09-2013)-UK-EN
• 16.1. Capacities and Specifications
• 16.2. Safety Precautions Maintenance and Repair
• 16.3. Counterweights
• 16.4. Hydraulic System
• 16.5. Steering System
• 16.6. Specifications
• 16.7. Turning Radius
• 16.8. Wheels and Tires
• 16.9. Battery Specifications
• 16.10. Capacities
• 16.11. Tilt Angles
• 16.12. Maximum Carriage and Tilt Creep Rates
• 16.13. Mast Speeds
• 16.14. Torque Specifications
• 16.15. Drive Axle
• 16.16. Differential and Speed Reducer
• 16.17. Brake System
• 16.18. Steering Axle
• 16.19. Tilt Cylinders
• 16.20. Hydraulic Pump and Motor
• 16.21. Hydraulic Tank
• 16.22. Hydraulic Control Valves
• 16.23. Manual Valve
• 16.24. Manual Handles and Levers
• 16.25. Manual Valve Covers
• 16.26. E-Hydraulic Valve
• 16.27. Electrical System
• 16.28. Adhesives and Sealants
• 16.29. Table 1. Manual Hydraulic Control Valve
• 16.30. Table 2. E-Hydraulic Control Valve
• 16.31. Table 3. E2.2-3.5XN (E45-70XN) (A268) Model Trucks
• 16.32. Table 4. Lift/Lower Speed, Standard Performance, 36 Volts
• 16.33. Table 5. Lift/Lower Speed, Standard Performance, 48 Volts
• 16.34. Table 6. Lift/Lower Speed Enhanced Performance, 48 Volts
• 16.35. Table 7. Lift/Lower Speed, Enhanced Performance, 80 Volts
• 17. RM1377-(03-2016)-UK-EN
• 17.1. SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES
• 17.2. SECTION 9025 TRACTION MOTOR
• 17.3. SECTION 9030 ELECTRICAL SYSTEM
• 17.4. SECTION 9035 DRIVE AXLE/UNIT
• 17.5. SECTION 9050 HYDRAULIC SYSTEMS
• 17.6. SECTION 9060 OPERATORS STATION
• 17.7. SECTION 9070 FRONT END (MAST) AND CHASSIS
• 17.8. SECTION 9080 SUPPLEMENTARY DATA
• 18. RM1364-(07-2015)-UK-EN
• 18.1. General
• 18.2. Safety Procedures When Working Near Mast
• 18.3. Maintenance Schedule
• 18.4. Maintenance Procedures Every Shift
• 18.5. Maintenance Procedures Every 1000 Hours or 6 months
• 18.6. Maintenance Procedures Every 2000 Hours or Yearly
• 18.7. Maintenance Procedures Every 4000 Hours Or Two Years
• 18.8. Battery Maintenance
• 18.9. Lift and Tilt System Leak Check
• 18.10. Lift Chain Adjustments
• 18.11. Welding Repairs
• 18.12. Overhead Guard Changes
• 18.13. Wheels and Tires
• 18.14. Adhesives and Sealants
• 19. RM1385-(06-2015)-UK-EN
• 19.1. General
• 19.2. Traction Motor Repair
• 19.3. Hydraulic Motor Repair
• 19.4. Torque Specifications
• 20. RM1384-(09-2014)-UK-EN
• 21. RM1446-(09-2014)-UK-EN
• 22. RM1620-(09-2015)-UK-EN
• 22.1. Proper Flushing after Major Hydraulic Repairs
• 22.2. Fluid Conditioning and System Flushing Procedures
• 22.3. Hydraulic Oil Sampling Method and Procedure
• 23. RM1668-(12-2014)-UK-EN
• 24. RM1669-(12-2014)-UK-EN