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Hyster A219 (E40HD E40 HSD) Service Manual – PDF DOWNLOAD
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Description
Hyster A219 (E40HD E40 HSD) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster A219 (E40HD E40 HSD) Service Manual – PDF DOWNLOAD
Language : English
Pages : 713
Downloadable : Yes
File Type : PDF
Size: 12.9 MB
TABLE OF CONTENTS:
Hyster A219 (E40HD E40 HSD) Service Manual – PDF DOWNLOAD
Binder1.............................................................................................. 1 Hyster-E40HD-Service-Manual-897076-0620SRM0294-(03-2008)-US-EN................................... 1 toc.......................................................................................... 1 DC Motor Maintenance..................................................................... 1 Safety Precautions Maintenance and Repair................................................ 2 General.................................................................................. 5 Brush and Commutator Inspection.......................................................... 5 Hydraulic Pump Motor and Traction Motor.............................................. 5 Steering Pump Motor.................................................................. 8 Normal Commutator Surface............................................................ 9 Commutator Problems.................................................................. 9 Brush Replacement........................................................................ 12 Stoning the Commutator................................................................... 14 Motors Repair............................................................................ 16 Disassemble.......................................................................... 16 Traction Motor and Hydraulic Pump Motor.......................................... 16 Steering Pump Motor.............................................................. 18 Assemble............................................................................. 20 Traction Motor and Hydraulic Pump Motor.......................................... 20 Steering Pump Motor.............................................................. 21 Brush Alignment, Traction and Hydraulic Motors........................................... 23 Tests for Damaged Field and Armature..................................................... 23 Test for an Open Circuit in One Armature Winding..................................... 23 Test for Short Circuit in One Armature Winding....................................... 24 Test for Short Circuit to Armature Shaft............................................. 24 Test for Open Circuit in Field Coil.................................................. 24 Test for Short Circuit in Field Coil................................................. 25 Test for Short Circuit Between Field and Motor Case.................................. 25 Brush Holder Test.................................................................... 25 Troubleshooting.......................................................................... 25 tables....................................................................................... 1 Table 1. Normal Commutator Surfaces...................................................... 8 Table 2. Commutator Problems............................................................. 9 Table 3. Brush Wear Replacement Guide.................................................... 12 Hyster-E40HD-Service-Manual-Capacities-and-specifications-1509901-8000SRM1002-(02-2007)-US-EN.... 31 toc.......................................................................................... 31 Capacities and Specifications............................................................ 31 Safety Precautions Maintenance and Repair................................................ 32 Lubrication Specifications............................................................... 35 Battery Size Specifications.............................................................. 35 Fuses.................................................................................... 36 Hydraulic System......................................................................... 36 Mast Speeds.............................................................................. 37 19cc Pump One-Speed Contactor........................................................ 37 19cc Pump Transistor Control......................................................... 37 Mast Tilt Performance.................................................................... 38 Motors (Voltage 36)...................................................................... 38 Tire Sizes............................................................................... 38 Torque Specifications.................................................................... 39 Frame................................................................................ 39 Transaxle............................................................................ 39 Wheels............................................................................... 39 Steering System...................................................................... 39 Hydraulic System..................................................................... 39 Mast/Tilt/Attachment Systems......................................................... 39 Control Settings......................................................................... 40 Hyster-E40HD-Service-Manual-Electrical-System01509894-2200SRM0995-(01-2007)-US-EN................ 43 toc.......................................................................................... 43 Electrical System........................................................................ 43 Safety Precautions Maintenance and Repair................................................ 44 General.................................................................................. 49 Major Electrical System Features......................................................... 50 Integrated System.................................................................... 50 CANbus Advantages.................................................................... 50 CANbus Communications................................................................ 51 Steering......................................................................... 51 Traction......................................................................... 51 Master Control Unit.............................................................. 51 Multifunction Control Handle......................................................... 51 Description/Features............................................................. 51 Remove........................................................................... 52 Disassemble...................................................................... 52 Tools Required............................................................... 52 Assemble......................................................................... 53 Install.......................................................................... 53 Operator Input Devices........................................................... 55 Multifunction Displays............................................................... 55 Standard Display................................................................. 55 Premium Display (Optional)....................................................... 55 BDI.................................................................................. 55 Setup.................................................................................... 56 Setup Instructions................................................................... 56 Curtis 1310 Master Control Unit.................................................. 56 Normal Operation..................................................................... 61 Standard Display................................................................. 61 Premium Display.................................................................. 61 Password Access.............................................................. 61 Startup Checklist............................................................ 62 Truck Operation Mode......................................................... 62 Diagnostics.......................................................................... 62 Power-On Self-Test............................................................... 63 Setup Menu Diagnostics........................................................... 63 Standard Display............................................................. 63 Premium Display.............................................................. 64 Checking Transistor Controller........................................................... 65 Component Repair and Testing......................................................... 65 Troubleshooting...................................................................... 66 Fault Codes and Display Messages..................................................... 67 SEM Traction Motor Controller............................................................ 77 Curtis 1243 Traction Controller...................................................... 78 Hydraulic Pump Controller (Optional)................................................. 78 Adjusting the Curtis 1254 Pump Controller Parameters............................. 78 Controller Removal................................................................... 79 Install.............................................................................. 79 Low-Voltage Protection Function...................................................... 80 Checking Contactor Coils............................................................. 80 Contactor and Electrical Panel Checks.................................................... 80 Fuses................................................................................ 80 Contactors........................................................................... 81 General.......................................................................... 81 Test............................................................................. 82 Tips............................................................................. 82 Disassemble and Assemble......................................................... 83 Steer Position Sensor.................................................................... 84 General.............................................................................. 84 Operation............................................................................ 84 Install.............................................................................. 84 Position Steer Tire for Straight Travel.............................................. 84 Adjust............................................................................... 85 Dash Display Method.............................................................. 85 Digital Voltmeter Method......................................................... 85 Test................................................................................. 86 Causes of Motor Failure.................................................................. 86 Overload............................................................................. 86 Shock Loading........................................................................ 86 Short in Field Coils................................................................. 86 Short Brushes........................................................................ 87 High or Low Commutator Bar........................................................... 87 Open Circuit......................................................................... 87 Low Battery Voltage.................................................................. 87 Eccentricity of Commutator........................................................... 87 Overspeeding......................................................................... 87 Drive Motor.............................................................................. 87 Inspect.............................................................................. 87 Preparation of Drive Motor Commutator................................................ 87 Drive Motor Brush and Brush Holder....................................................... 89 Drive Motor Brush, Remove and Install (Motor Installed).............................. 89 Drive Motor Brush Holder, Remove and Install (Motor Installed)....................... 89 Drive Motor Disassembly and Assembly..................................................... 90 Remove............................................................................... 90 Repair............................................................................... 90 Disassemble...................................................................... 90 Assemble......................................................................... 90 Install.............................................................................. 91 Drive and Hydraulic Pump Motors.......................................................... 92 Routine Preventive Maintenance....................................................... 92 Preventive Maintenance Checks.................................................... 92 Cleanliness.......................................................................... 93 Connections.......................................................................... 93 Discoloration and Burn Marks......................................................... 93 Brushes.............................................................................. 93 Short in Armature.................................................................... 93 Commutator........................................................................... 93 Bearings............................................................................. 93 Hoist Pump Motor......................................................................... 94 Maintenance Instructions............................................................. 94 Remove........................................................................... 94 Repair........................................................................... 94 Disassemble.................................................................. 94 Assemble..................................................................... 96 Install.......................................................................... 96 Motor Tests.............................................................................. 96 Excessive Current Draw............................................................... 96 Measuring Current Draw............................................................... 96 Excessive Resistance................................................................. 97 Brush Springs........................................................................ 97 DC to DC Converter....................................................................... 97 tables....................................................................................... 43 Table 1. Fault Codes and Display Messages................................................ 67 Table 2. 1254 Hydraulic Pump Controller Parameter Settings............................... 79 Table 3. Coil Resistance................................................................. 82 Table 4. Potentiometer Specifications.................................................... 86 Hyster-E40HD-Service-Manual-Electric-Brake-System-1509896-1800SRM0997-(09-2001)-US-EN............101 toc..........................................................................................101 Electric Brake System....................................................................101 Safety Precautions Maintenance and Repair................................................102 General..................................................................................105 Description and Operation................................................................105 Electric Brake Repair....................................................................105 Inspect..............................................................................105 Remove...............................................................................106 Adjust...............................................................................107 Install..............................................................................107 Electric Brake Operational Check.........................................................108 Brake Pedal Assembly.....................................................................108 Remove...............................................................................108 Install..............................................................................109 Repair...............................................................................109 Bushings and Spring..............................................................110 Remove.......................................................................110 Install......................................................................110 Brake Switch Assembly............................................................110 Remove.......................................................................110 Install......................................................................110 Adjust.......................................................................110 Troubleshooting..........................................................................111 Hyster-E40HD-Service-Manual-Frame-1509893-0100SRM0994-(02-2002)-US-EN............................115 toc..........................................................................................115 Frame....................................................................................115 Safety Precautions Maintenance and Repair................................................116 General..................................................................................119 Frame....................................................................................119 Size.................................................................................119 Painting Instructions................................................................119 Covers and Pads..........................................................................120 Covers...............................................................................120 Remove...........................................................................120 Install..........................................................................120 Pads.................................................................................120 Remove...........................................................................120 Install..........................................................................121 Overhead Guard...........................................................................122 Description..........................................................................122 Remove...............................................................................122 Repair...............................................................................122 Install..............................................................................122 Battery..................................................................................123 Battery Sizes........................................................................123 Labels and Decals........................................................................125 Safety Labels........................................................................125 tables.......................................................................................115 Table 1. 3000 lb Capacity, 43.9-inch Wheel Base..........................................124 Table 2. 3500 lb Capacity, 43.9-inch Wheel Base..........................................124 Table 3. 3500 lb Capacity, 46.4-inch Wheel Base..........................................124 Table 4. 4000 lb Capacity, 46.4-inch Wheel Base..........................................125 Hyster-E40HD-Service-Manual-Hydraulic-System-1509897-1900SRM0998-(09-2006)-US-EN.................131 toc..........................................................................................131 Hydraulic System.........................................................................131 Safety Precautions Maintenance and Repair................................................132 General..................................................................................135 Hoses................................................................................135 Fittings.............................................................................135 Multifunction Control Handle.............................................................136 Description..........................................................................136 Manual Lowering..........................................................................137 How to Lower Mast Manually...........................................................137 Main Hydraulic Control Valve.............................................................137 Description..........................................................................137 Check and Adjust.....................................................................138 Manifold Pressures...............................................................138 Counterbalance Valve.............................................................138 Remove...............................................................................138 Repair...............................................................................139 Disassemble......................................................................139 Clean............................................................................140 Assemble.........................................................................140 Install..............................................................................141 Lift Pump and Motor......................................................................142 Description..........................................................................142 Remove...............................................................................142 Motor............................................................................143 Lift Pump........................................................................144 Install..............................................................................144 Lift Pump........................................................................144 Motor............................................................................144 Lift Pump................................................................................145 Description..........................................................................145 Disassemble..........................................................................146 Assemble.............................................................................146 Hydraulic Tank...........................................................................147 Inspect..............................................................................147 Remove...............................................................................147 Clean................................................................................149 Steam Method.....................................................................149 Trisodium Phosphate Method.......................................................149 Install..............................................................................150 Troubleshooting..........................................................................151 tables.......................................................................................131 Table 1. Pressure Settings...............................................................138 Table 2. Main Hydraulic Control Valve Cartridges.........................................141 Hyster-E40HD-Service-Manual-Master-Drive-Unit-1509892-0630SRM0993-(12-2001)-US-EN................155 Hyster-E40HD-Service-Manual-Periodic-Maintenance-1495940-8000SRM0991-(02-2010)-US-EN.............173 toc..........................................................................................173 Periodic Maintenance.....................................................................173 Safety Precautions Maintenance and Repair................................................174 General..................................................................................177 How to Move Disabled Lift Truck......................................................177 How to Tow Lift Truck............................................................177 How to Put Lift Truck on Blocks......................................................178 How to Raise Load Wheels.........................................................178 How to Raise Steer Wheel.........................................................179 How to Clean a Lift Truck............................................................179 Lift and Tilt System Leak Checks.........................................................180 Lift System..........................................................................180 Tilt System..........................................................................180 Safety Procedures When Working Near Mast.................................................181 Check Operation..........................................................................182 Gauges and Horn......................................................................182 Control Handle.......................................................................182 Steering System......................................................................182 Maintenance Schedule.....................................................................182 Maintenance Procedures Every 8 Hours or Daily............................................187 Before Operation Checks..............................................................187 Hydraulic System.................................................................188 Battery..........................................................................188 Battery Restraint System.........................................................189 Mast, Forks, and Lift Chains.....................................................189 Tires and Wheels.................................................................190 Maintenance Procedures Every 350 Hours or 3 Months.......................................191 Hydraulic System.....................................................................191 Wheel Nut Torque.....................................................................191 Transaxle............................................................................191 Lift System Operation................................................................191 Mast.................................................................................192 Lift Chains..........................................................................192 Forks................................................................................193 Safety Labels........................................................................193 Other Lubrication....................................................................193 Electrical Inspection................................................................194 Special Precautions..............................................................194 Contactors.......................................................................195 Motor Brushes....................................................................195 Maintenance Procedures Every 2000 Hours or Yearly........................................196 Hydraulic System.....................................................................196 Brakes...............................................................................196 Transaxle............................................................................196 Battery Maintenance......................................................................197 How to Charge the Battery............................................................197 How to Change the Battery............................................................198 Lift Chain Adjustments...................................................................198 Forks....................................................................................199 Remove...............................................................................199 Inspect..............................................................................199 Install..............................................................................200 Wheels and Tires Maintenance.............................................................200 General..............................................................................200 Wheels and Tires.....................................................................200 Remove the Wheel From Lift Truck.................................................200 Install the Tire on Wheel........................................................200 Install the Wheel and Tire...........................................................201 tables.......................................................................................173 Table 1. Maintenance Schedule............................................................183 Table 2. Transaxle Capacity..............................................................196 Hyster-E40HD-Service-Manual-Report-an-Error......................................................205 Hyster-E40HD-Service-Manual-Tilt-Cylinders-1509898-2100SRM0999-(04-2003)-US-EN...................206 toc..........................................................................................206 Tilt Cylinders...........................................................................206 Safety Precautions Maintenance and Repair................................................207 General..................................................................................210 Description..............................................................................210 Tilt Cylinder Repair.....................................................................210 Remove...............................................................................210 Disassemble..........................................................................210 Clean................................................................................210 Assemble.............................................................................214 Install..............................................................................214 Tilt Cylinder Leak Check.................................................................215 Mast Tilt Angle Adjustment...............................................................215 Troubleshooting..........................................................................215 Binder2..............................................................................................220 897076-0620SRM0294-(08-2003)-US..................................................................220 toc..........................................................................................220 DC Motor Maintenance.....................................................................220 Safety Precautions Maintenance and Repair................................................221 General..................................................................................224 Brush and Commutator Inspection..........................................................224 Hydraulic Pump Motor and Traction Motor..............................................224 Steering Pump Motor..................................................................227 Normal Commutator Surface............................................................227 Commutator Problems..................................................................227 Brush Replacement........................................................................231 Stoning the Commutator...................................................................233 Motors Repair............................................................................235 Disassemble..........................................................................235 Traction Motor and Hydraulic Pump Motor..........................................235 Steering Pump Motor..............................................................239 Assemble.............................................................................239 Traction Motor and Hydraulic Pump Motor..........................................239 Steering Pump Motor..............................................................240 Brush Alignment, Traction and Hydraulic Motors...........................................243 Tests for Damaged Field and Armature.....................................................243 Test for an Open Circuit in Armature.................................................243 Test for Short Circuit in One Armature Winding.......................................244 Test for Short Circuit to Armature Shaft.............................................244 Test for Open Circuit in Field Coil..................................................244 Test for Short Circuit in Field Coil.................................................244 Test for Short Circuit between Field and Motor Case..................................245 Brush Holder Test....................................................................245 Troubleshooting..........................................................................245 tables.......................................................................................220 Table 1. Normal Commutator Surfaces......................................................226 Table 2. Commutator Problems.............................................................227 Table 3. Brush Wear Replacement Guide....................................................231 897991-8000SRM0663-(08-2002)-UK..................................................................250 toc..........................................................................................250 Diagrams.................................................................................250 Safety Precautions Maintenance and Repair................................................251 897991-8000SRM0663-(08-2002)-US..................................................................282 toc..........................................................................................282 Diagrams.................................................................................282 Safety Precautions Maintenance and Repair................................................283 899648-2240SRM0001-(11-2003)-US..................................................................314 toc..........................................................................................314 Industrial Battery.......................................................................314 Safety Precautions Maintenance and Repair................................................315 General..................................................................................318 Lead-Acid Batteries......................................................................318 Specific Gravity.........................................................................319 Chemical Reaction in a Cell..............................................................319 Electrical Terms.........................................................................320 Battery Selection........................................................................321 Battery Voltage..........................................................................322 Battery as a Counterweight...............................................................322 Battery Ratings..........................................................................322 Kilowatt-Hours.......................................................................322 Battery Maintenance......................................................................323 Safety Procedures....................................................................323 Maintenance Records..................................................................323 New Battery..........................................................................323 Cleaning Battery.....................................................................324 Adding Water to Battery..............................................................325 Hydrometer...........................................................................326 Battery Temperature..................................................................326 Charging Battery.....................................................................327 Types of Battery Charges.........................................................328 Methods of Charging..............................................................329 Troubleshooting Charger..........................................................330 Knowing When Battery Is Fully Charged............................................330 Where to Charge Batteries............................................................330 Equipment Needed.................................................................330 Battery Connectors...................................................................331 Battery Care.........................................................................331 tables.......................................................................................314 Table 1. Battery Capacity Terms..........................................................322 1495940-8000SRM0991-(04-2002)-US.................................................................336 toc..........................................................................................336 Periodic Maintenance.....................................................................336 Safety Precautions Maintenance and Repair................................................337 General..................................................................................340 How to Move Disabled Lift Truck......................................................340 How to Tow Lift Truck............................................................340 How to Put Lift Truck on Blocks......................................................341 How to Raise Load Wheels.........................................................341 How to Raise Steer Wheel.........................................................342 Lift and Tilt System Leak Checks.........................................................342 Lift System..........................................................................342 Tilt System..........................................................................343 Safety Procedures When Working Near Mast.................................................343 Check Operation..........................................................................344 Gauges and Horn......................................................................344 Control Handle.......................................................................344 Steering System......................................................................344 Maintenance Schedule.....................................................................345 Maintenance Procedures Every 8 Hours or Daily............................................348 Before Operation Checks..............................................................348 Hydraulic System.................................................................349 Battery..........................................................................349 Battery Restraint System.........................................................350 Tires and Wheels.................................................................350 Maintenance Procedures Every 350 Hours or 3 Months.......................................351 Hydraulic Tank Breather..............................................................351 Wheel Nut Torque.....................................................................351 Transaxle............................................................................351 Lift System Operation................................................................351 Mast.................................................................................351 Lift Chains..........................................................................352 Forks................................................................................352 Safety Labels........................................................................353 Other Lubrication....................................................................353 Electrical Inspection................................................................353 Special Precautions..............................................................353 Contactors.......................................................................354 Motor Brushes....................................................................355 Maintenance Procedures Every 2000 Hours or Yearly........................................355 Hydraulic System.....................................................................355 Change the Hydraulic Oil Filter..................................................355 Check the Hydraulic Oil Strainer.................................................355 Change the Hydraulic Oil.........................................................355 Brakes...............................................................................355 Transaxle............................................................................355 Battery Maintenance......................................................................356 How to Charge the Battery............................................................356 How to Change the Battery............................................................357 Wheels and Tires Maintenance.............................................................357 General..............................................................................357 Wheels and Tires.....................................................................357 Remove the Wheel From Lift Truck.................................................357 Install the Tire on Wheel........................................................357 Install the Wheel and Tire...........................................................358 Mast and Lift Chains.....................................................................358 Forks....................................................................................359 Adjust...............................................................................359 Remove...............................................................................359 Inspect..............................................................................359 Install..............................................................................359 tables.......................................................................................336 Table 1. Maintenance Schedule............................................................346 Table 2. Transaxle Capacity..............................................................355 1495941-8000SRM0992-(01-2003)-US.................................................................364 toc..........................................................................................364 Diagrams.................................................................................364 Safety Precautions Maintenance and Repair................................................365 1495941-8000SRM0992-(01-2003)-US-EN..............................................................384 toc..........................................................................................384 Diagrams.................................................................................384 Safety Precautions Maintenance and Repair................................................385 1495941-8000SRM0992-(02-2007)-US-EN..............................................................404 toc..........................................................................................404 Diagrams.................................................................................404 Safety Precautions Maintenance and Repair................................................405 1495941-8000SRM0992-(10-2004)-US-EN..............................................................422 toc..........................................................................................422 Diagrams.................................................................................422 Safety Precautions Maintenance and Repair................................................423 1509204-5000SRM0990-(09-2001)-UK.................................................................438 toc..........................................................................................438 Empty Container Handling Attachment......................................................438 Safety Precautions Maintenance and Repair................................................439 General..................................................................................442 Description..............................................................................442 Operation................................................................................453 General..............................................................................453 Selector Valves......................................................................453 Sideshift Circuit....................................................................453 Extend and Retract Circuit...........................................................453 Twist Lock Circuit and Control.......................................................453 Model 572 - Double Horizontally Mounted..........................................453 Model 573 - Horizontally Mounted.................................................454 Model 578 - Vertically Mounted...................................................454 Lifting Hooks........................................................................454 Model 575........................................................................454 Indicator Lights and LEDs............................................................454 Lift Interrupt and Override..........................................................455 Overlowering Interrupt and Override..................................................455 Second Container Detection Sensor (Model 572 Only)...................................455 Carriage and Attachment Repair...........................................................456 Remove...............................................................................456 Attachment Without Carriage Repair.......................................................456 Remove...............................................................................456 Sideshift Cylinders Repair...............................................................457 Remove...............................................................................457 Disassemble..........................................................................457 Assemble.............................................................................457 Extension Cylinders Repair...............................................................458 Remove...............................................................................458 Disassemble..........................................................................458 Clean and Inspect....................................................................459 Assemble.............................................................................459 Install..............................................................................459 Floating End Beams Repair................................................................460 Remove...............................................................................460 Install..............................................................................460 Hose Replacement In End Beams........................................................460 Twist Locks Repair for Model 572 and 573.................................................460 Remove...............................................................................460 Model 573........................................................................460 Model 572........................................................................460 Disassemble..........................................................................461 Clean and Inspect....................................................................461 Assemble.............................................................................461 Hook Replacement for Model 575...........................................................462 Inspect..............................................................................462 Remove...............................................................................462 Install..............................................................................462 Twist Locks Repair for Model 578.........................................................463 Disassemble..........................................................................463 Clean and Inspect....................................................................463 Assemble.............................................................................463 Extension Beams Repair...................................................................464 LH and RH Extension Beam, Remove.....................................................464 Slave Beam, Remove...................................................................464 Clean and Inspect....................................................................465 Assemble.............................................................................465 Bleed the System.........................................................................466 Valve Assembly...........................................................................466 Slide Pad Replacement....................................................................467 Adjustments..............................................................................468 Twist Lock Angle Adjustment..........................................................468 Model 578 Only...................................................................468 LOCKED/NOT LOCKED Sensors Adjustment.................................................468 Model 573........................................................................468 Model 578........................................................................468 Seated Sensor Adjustment.............................................................469 Model 572 and 573................................................................469 Model 578........................................................................470 Overlowering Protection Sensor Adjustment (Models 572, 573, and .....................470 Torque Chart.........................................................................470 Maintenance..............................................................................471 Additional Attachment Maintenance....................................................474 Interface boxes with LED Indicators..................................................474 Models 572, 573, 575, and 578: Interface Box with LED Indicators.................474 Models 573 and 578: Two Additional Interface Boxes with LED Indi.................475 Model 572........................................................................475 Troubleshooting..........................................................................476 tables.......................................................................................438 Table 1. Torque Chart....................................................................470 Table 2. Maintenance Schedule............................................................471 1509892-0630SRM0993-(12-2001)-US.................................................................506 1509894-2200SRM0995-(01-2007)-US-EN..............................................................524 toc..........................................................................................524 Electrical System........................................................................524 Safety Precautions Maintenance and Repair................................................525 General..................................................................................530 Major Electrical System Features.........................................................531 Integrated System....................................................................531 CANbus Advantages....................................................................531 CANbus Communications................................................................532 Steering.........................................................................532 Traction.........................................................................532 Master Control Unit..............................................................532 Multifunction Control Handle.........................................................532 Description/Features.............................................................532 Remove...........................................................................533 Disassemble......................................................................533 Tools Required...............................................................533 Assemble.........................................................................534 Install..........................................................................534 Operator Input Devices...........................................................536 Multifunction Displays...............................................................536 Standard Display.................................................................536 Premium Display (Optional).......................................................536 BDI..................................................................................536 Setup....................................................................................537 Setup Instructions...................................................................537 Curtis 1310 Master Control Unit..................................................537 Normal Operation.....................................................................542 Standard Display.................................................................542 Premium Display..................................................................542 Password Access..............................................................542 Startup Checklist............................................................543 Truck Operation Mode.........................................................543 Diagnostics..........................................................................543 Power-On Self-Test...............................................................544 Setup Menu Diagnostics...........................................................544 Standard Display.............................................................544 Premium Display..............................................................545 Checking Transistor Controller...........................................................546 Component Repair and Testing.........................................................546 Troubleshooting......................................................................547 Fault Codes and Display Messages.....................................................548 SEM Traction Motor Controller............................................................558 Curtis 1243 Traction Controller......................................................559 Hydraulic Pump Controller (Optional).................................................559 Adjusting the Curtis 1254 Pump Controller Parameters.............................559 Controller Removal...................................................................560 Install..............................................................................560 Low-Voltage Protection Function......................................................561 Checking Contactor Coils.............................................................561 Contactor and Electrical Panel Checks....................................................561 Fuses................................................................................561 Contactors...........................................................................562 General..........................................................................562 Test.............................................................................563 Tips.............................................................................563 Disassemble and Assemble.........................................................564 Steer Position Sensor....................................................................565 General..............................................................................565 Operation............................................................................565 Install..............................................................................565 Position Steer Tire for Straight Travel..............................................565 Adjust...............................................................................566 Dash Display Method..............................................................566 Digital Voltmeter Method.........................................................566 Test.................................................................................567 Causes of Motor Failure..................................................................567 Overload.............................................................................567 Shock Loading........................................................................567 Short in Field Coils.................................................................567 Short Brushes........................................................................568 High or Low Commutator Bar...........................................................568 Open Circuit.........................................................................568 Low Battery Voltage..................................................................568 Eccentricity of Commutator...........................................................568 Overspeeding.........................................................................568 Drive Motor..............................................................................568 Inspect..............................................................................568 Preparation of Drive Motor Commutator................................................568 Drive Motor Brush and Brush Holder.......................................................570 Drive Motor Brush, Remove and Install (Motor Installed)..............................570 Drive Motor Brush Holder, Remove and Install (Motor Installed).......................570 Drive Motor Disassembly and Assembly.....................................................571 Remove...............................................................................571 Repair...............................................................................571 Disassemble......................................................................571 Assemble.........................................................................571 Install..............................................................................572 Drive and Hydraulic Pump Motors..........................................................573 Routine Preventive Maintenance.......................................................573 Preventive Maintenance Checks....................................................573 Cleanliness..........................................................................574 Connections..........................................................................574 Discoloration and Burn Marks.........................................................574 Brushes..............................................................................574 Short in Armature....................................................................574 Commutator...........................................................................574 Bearings.............................................................................574 Hoist Pump Motor.........................................................................575 Maintenance Instructions.............................................................575 Remove...........................................................................575 Repair...........................................................................575 Disassemble..................................................................575 Assemble.....................................................................577 Install..........................................................................577 Motor Tests..............................................................................577 Excessive Current Draw...............................................................577 Measuring Current Draw...............................................................577 Excessive Resistance.................................................................578 Brush Springs........................................................................578 DC to DC Converter.......................................................................578 tables.......................................................................................524 Table 1. Fault Codes and Display Messages................................................548 Table 2. 1254 Hydraulic Pump Controller Parameter Settings...............................560 Table 3. Coil Resistance.................................................................563 Table 4. Potentiometer Specifications....................................................567 1509894-2200SRM0995-(09-2004)-US-EN..............................................................582 toc..........................................................................................582 Electrical System........................................................................582 Safety Precautions Maintenance and Repair................................................583 General..................................................................................588 Major Electrical System Features.........................................................589 Integrated System....................................................................589 CAN Bus Advantages...................................................................589 CAN Bus Communications...............................................................590 Steering.........................................................................590 Traction.........................................................................590 Master Control Unit..............................................................590 Multifunction Control Handle.........................................................590 Description/Features.............................................................590 Remove...........................................................................591 Disassemble......................................................................591 Tools Required...............................................................591 Assemble.........................................................................594 Install..........................................................................594 Operator Input Devices...........................................................594 Multifunction Displays...............................................................594 Standard Display.................................................................594 Premium Display (Optional).......................................................594 BDI..................................................................................594 Setup....................................................................................595 Setup Instructions...................................................................595 Curtis 1310 Master Control Unit..................................................595 Normal Operation.....................................................................600 Standard Display.................................................................600 Premium Display..................................................................600 Password Access..............................................................600 Startup Checklist............................................................600 Truck Operation Mode.........................................................601 Diagnostics..........................................................................601 Power-On Self-Test...............................................................601 Run-Time Diagnostic..............................................................602 Standard Display.............................................................602 Premium Display..............................................................603 Checking Transistor Controller...........................................................604 Component Repair and Testing.........................................................604 Troubleshooting......................................................................605 Fault Codes and Display Messages.....................................................606 SEM Traction Motor Controller............................................................616 Curtis 1243 Traction Controller......................................................616 Hydraulic Pump Controller (Optional).................................................616 Adjusting the Curtis 1254 Pump Controller Parameters.............................617 Controller Removal...................................................................618 Install..............................................................................618 Low-Voltage Protection Function......................................................618 Checking Contactor Coils.............................................................618 Contactor and Electrical Panel Checks....................................................619 Fuses................................................................................619 Contactors...........................................................................620 General..........................................................................620 Test.............................................................................620 Tips.............................................................................621 Disassemble and Assemble.........................................................621 Steer Position Sensor....................................................................623 General..............................................................................623 Operation............................................................................623 Install..............................................................................623 Position Steer Tire for Straight Travel..............................................623 Adjust...............................................................................624 Dash Display Method..............................................................624 Digital Voltmeter Method.........................................................624 Test.................................................................................625 Causes of Motor Failure..................................................................625 Overload.............................................................................625 Shock Loading........................................................................625 Short in Field Coils.................................................................625 Short Brushes........................................................................625 High or Low Commutator Bar...........................................................625 Open Circuit.........................................................................625 Low Battery Voltage..................................................................625 Eccentricity of Commutator...........................................................626 Overspeeding.........................................................................626 Drive Motor..............................................................................626 Inspect..............................................................................626 Preparation of Drive Motor Commutator................................................626 Drive Motor Brush and Brush Holder.......................................................627 Drive Motor Brush, Remove and Install (Motor Installed)..............................627 Drive Motor Brush Holder, Remove and Install (Motor Installed).......................627 Drive Motor Disassembly and Assembly.....................................................628 Remove...............................................................................628 Repair...............................................................................628 Disassemble......................................................................628 Assemble.........................................................................628 Install..............................................................................630 Drive and Hydraulic Pump Motors..........................................................630 Routine Preventive Maintenance.......................................................630 Preventive Maintenance Checks....................................................630 Cleanliness..........................................................................631 Connections..........................................................................631 Discoloration and Burn Marks.........................................................631 Brushes..............................................................................631 Short in Armature....................................................................631 Commutator...........................................................................631 Bearings.............................................................................631 Hoist Pump Motor.........................................................................632 Maintenance Instructions.............................................................632 Remove...........................................................................632 Repair...........................................................................632 Disassemble..................................................................632 Assemble.....................................................................632 Install..........................................................................634 Motor Tests..............................................................................634 Excessive Current Draw...............................................................634 Measuring Current Draw...............................................................634 Excessive Resistance.................................................................635 Brush Springs........................................................................635 DC to DC Converter.......................................................................635 tables.......................................................................................582 Table 1. Fault Codes and Display Messages................................................606 Table 2. 1254 Hydraulic Pump Controller Parameter Settings...............................617 Table 3. Coil Resistance.................................................................620 Table 4. Potentiometer Specifications....................................................625 1509895-1600SRM0996-(11-2003)-US.................................................................638 toc..........................................................................................638 Steering System..........................................................................638 Safety Precautions Maintenance and Repair................................................639 General..................................................................................642 Description and Features.................................................................642 On-Demand Steering Circuit...............................................................643 Description..........................................................................643 Steering Control Handle..............................................................644 Remove...........................................................................644 Install..........................................................................644 Steering Sensor......................................................................644 Test.............................................................................644 Remove...........................................................................644 Install..........................................................................644 Steering Control Unit (SCU)..............................................................645 Description..........................................................................645 Inspect..............................................................................645 Remove...............................................................................645 Repair...............................................................................645 Replace..............................................................................647 Steering Pump and Motor Assembly.........................................................647 Description..........................................................................647 Inspect..............................................................................647 Remove...............................................................................648 Repair...............................................................................648 Disassembly......................................................................648 Assembly.........................................................................649 Install..............................................................................650 Power Steering Pump......................................................................650 Description..........................................................................650 Repair...............................................................................650 Disassemble......................................................................650 Assembly.........................................................................651 Steer Unit Actuator-Kordel™..............................................................652 Description..........................................................................652 Inspect..............................................................................652 Remove...............................................................................652 Repair...............................................................................654 Disassemble......................................................................654 Clean............................................................................654 Assemble.........................................................................654 Install..............................................................................656 Checks and Adjustments...................................................................657 Air in System........................................................................657 Operation Check......................................................................657 Steering Pressure....................................................................657 Troubleshooting..........................................................................658 1509896-1800SRM0997-(09-2001)-US.................................................................664 toc..........................................................................................664 Electric Brake System....................................................................664 Safety Precautions Maintenance and Repair................................................665 General..................................................................................668 Description and Operation................................................................668 Electric Brake Repair....................................................................668 Inspect..............................................................................668 Remove...............................................................................669 Adjust...............................................................................670 Install..............................................................................670 Electric Brake Operational Check.........................................................671 Brake Pedal Assembly.....................................................................671 Remove...............................................................................671 Install..............................................................................672 Repair...............................................................................672 Bushings and Spring..............................................................673 Remove.......................................................................673 Install......................................................................673 Brake Switch Assembly............................................................673 Remove.......................................................................673 Install......................................................................673 Adjust.......................................................................673 Troubleshooting..........................................................................674 1509897-1900SRM0998-(06-2004)-US-EN..............................................................678 toc..........................................................................................678 Hydraulic System.........................................................................678 Safety Precautions Maintenance and Repair................................................679 General..................................................................................682 Multifunction Control Handle.............................................................682 Description..........................................................................682 Manual Lowering..........................................................................683 How to lower mast manually...........................................................683 Main Hydraulic Control Valve.............................................................683 Description..........................................................................683 Check and Adjust.....................................................................684 Manifold Pressures...............................................................684 Counter Balance Valve............................................................684 Remove...............................................................................684 Repair...............................................................................685 Disassemble......................................................................685 Clean............................................................................686 Assemble.........................................................................686 Install..............................................................................687 Lift Pump and Motor......................................................................688 Description..........................................................................688 Remove...............................................................................688 Motor............................................................................689 Lift Pump........................................................................690 Install..............................................................................690 Lift Pump........................................................................690 Motor............................................................................690 Lift Pump................................................................................691 Description..........................................................................691 Disassemble..........................................................................692 Assembly.............................................................................692 Hydraulic Tank...........................................................................693 Inspect..............................................................................693 Remove...............................................................................693 Clean................................................................................695 Steam Method.....................................................................695 Trisodium Phosphate Method.......................................................696 Install..............................................................................696 Troubleshooting..........................................................................697 tables.......................................................................................678 Table 1. Pressure Settings...............................................................684 Table 2. Main Hydraulic Control Valve Cartridges.........................................687 1509901-8000SRM1002-(06-2004)-US-EN..............................................................702 toc..........................................................................................702 Capacities and Specifications............................................................702 Safety Precautions Maintenance and Repair................................................703 Battery Size Specifications..............................................................706 Fuses....................................................................................707 Hydraulic System.........................................................................707 Mast Speeds..............................................................................708 19cc Pump One-Speed Contactor........................................................708 19cc Pump Transistor Control.........................................................708 Mast Tilt Performance....................................................................709 Motors (Voltage 36)......................................................................709 Tire Sizes...............................................................................709 Torque Specifications....................................................................709 Frame................................................................................709 Transaxle............................................................................709 Wheels...............................................................................710 Steering System......................................................................710 Hydraulic System.....................................................................710 Mast/Tilt/Attachment Systems.........................................................710 Control Settings.........................................................................711
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