Hyster Industrial Battery All Electric Lift Truck Maintenance And Repair

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Hyster Industrial Battery All Electric Lift Truck Maintenance And Repair

$30.00

Type Of Manual: Maintenance And Repair
Number of Pages: 3174
Size: 167.5MB
Format: PDF

Category: Hyster Service Manual PDF

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

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