Hyster DC Motor All Electric Lift Truck Maintenance And Repair

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Hyster DC Motor All Electric Lift Truck Maintenance And Repair

$30.00

Type Of Manual: Maintenance And Repair
Number of Pages: 1520
Size: 61.9MB
Format: PDF

Category: Hyster Service Manual PDF

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)

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