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Hyster A268 Service Manual – PDF DOWNLOAD
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Description
Hyster A268 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A268 Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies,make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOWTO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster A268 Service Manual – PDF DOWNLOAD
1........................................................................................... 1 Brakes.................................................................................. 1 toc................................................................................. 1 Brake System.................................................................... 1 Safety Precautions Maintenance and Repair....................................... 2 General......................................................................... 5 Dry Brake System............................................................ 5 Service Brakes Repair (Dry Brake)............................................... 6 Remove and Disassemble...................................................... 6 Clean....................................................................... 9 Inspect..................................................................... 10 Assemble and Install........................................................ 10 Adjust...................................................................... 16 Parking Brake Repair............................................................ 16 Remove and Disassemble...................................................... 16 Inspect..................................................................... 19 Assemble and Install........................................................ 19 Adjust...................................................................... 21 Master Cylinder Repair.......................................................... 22 Remove...................................................................... 22 Disassemble................................................................. 22 Clean....................................................................... 23 Inspect..................................................................... 23 Assemble.................................................................... 24 Bench Bleed Master Cylinder................................................. 24 Install and Adjust.......................................................... 24 Brake Pedal Components.......................................................... 25 Remove...................................................................... 25 Disassemble................................................................. 27 Inspect..................................................................... 27 Assemble.................................................................... 27 Install..................................................................... 27 Automatic Park Brake............................................................ 28 General..................................................................... 28 Remove...................................................................... 28 Manual Release Handle................................................... 28 Automatic Park Brake Assembly........................................... 30 Automatic Park Brake Module............................................. 30 Disassemble................................................................. 30 Clean and Inspect........................................................... 30 Assemble.................................................................... 31 Install..................................................................... 31 Automatic Park Brake Module............................................. 31 Manual Release Handle................................................... 31 Automatic Park Brake Assembly........................................... 31 Adjustments................................................................. 31 Service Brakes Adjustment (Dry Brake)........................................... 31 Brake Adjust................................................................ 31 Parking Brake Adjustment........................................................ 33 Brake System Air Removal........................................................ 33 Brake System Air Removal.................................................... 33 Using Pressure Bleed System................................................. 33 Using Brake Pedal Pressure.................................................. 33 Brake Pedal Adjustment.......................................................... 34 Brake Pedal Adjustment...................................................... 34 Master Cylinder Adjustment...................................................... 35 Adjust Push Rod............................................................. 35 Parking Brake Not Applied Switch Test........................................... 35 Torque Specifications........................................................... 36 Cab..................................................................................... 39 toc................................................................................. 39 Operator's Cab.................................................................. 39 Safety Precautions Maintenance and Repair....................................... 40 Window Replacement.............................................................. 43 Front Panel................................................................. 43 Remove.................................................................. 43 Clean................................................................... 43 Inspect................................................................. 44 Install................................................................. 44 Rear Panel.................................................................. 44 Remove.................................................................. 44 Clean................................................................... 47 Inspect................................................................. 47 Install................................................................. 47 Door Window................................................................. 48 Disassemble Window...................................................... 48 Clean................................................................... 49 Inspect................................................................. 49 Assemble Window......................................................... 49 Window Wipers Replacement....................................................... 49 Front Wiper Assembly........................................................ 49 Remove.................................................................. 49 Clean................................................................... 53 Inspect................................................................. 53 Install................................................................. 53 Cab Component Repair............................................................ 54 Roof Liner.................................................................. 54 Remove.................................................................. 54 Clean................................................................... 55 Inspect................................................................. 55 Install................................................................. 55 Top Panel................................................................... 55 Remove.................................................................. 55 Clean................................................................... 57 Inspect................................................................. 57 Install................................................................. 57 Cab Door Assembly............................................................... 58 Door Assembly............................................................... 58 Remove.................................................................. 58 Disassemble Left Door................................................... 61 Disassemble Right Door.................................................. 63 Clean................................................................... 63 Inspect................................................................. 63 Assemble Right Door..................................................... 65 Assemble Left Door...................................................... 65 Install................................................................. 65 Cab Heater...................................................................... 66 Cab Heater.................................................................. 66 Remove.................................................................. 66 Clean................................................................... 66 Inspect................................................................. 66 Install................................................................. 69 Troubleshooting......................................................... 69 Weather Panel Replacement for Lift Truck Model E2.2-3.5XN (E45-7................ 72 Remove...................................................................... 72 Roof Panels............................................................. 72 Front Screen Panel...................................................... 72 Install..................................................................... 74 Front Screen Panel...................................................... 74 Roof Panels............................................................. 75 tables.............................................................................. 39 Table 1. Connector C1........................................................... 71 Table 2. Connector C2........................................................... 71 Table 3. Connector C3........................................................... 71 Table 4. Connector C4........................................................... 71 Table 5. Connector C5........................................................... 71 Table 6. Connector C6........................................................... 71 Table 7. Connector C7........................................................... 71 Control Valve........................................................................... 79 toc................................................................................. 79 Main Control Valves............................................................. 79 Safety Precautions Maintenance and Repair....................................... 80 General......................................................................... 85 Lift Trucks J1.5-2.0XNT (J30-40XNT) (K160) and J1.6-2.0XN (J30-4............ 85 Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and J2.2-3.5XN (J45-70X............ 86 Discharging the Capacitors.................................................. 89 Manual Hydraulic Control Valve Repair for Lift Truck J1.5-2.0XNT................ 90 Remove...................................................................... 90 Beginning Steps......................................................... 90 Disassemble Covers, Links, and Levers................................... 91 Disassemble Handles and Levers.............................................. 102 Disassemble Manual Control Valve............................................ 104 Spool Seal Replacement...................................................... 111 Clean....................................................................... 114 Inspect..................................................................... 114 Assemble Manual Control Valve............................................... 115 Assemble Handles and Levers................................................. 123 Install..................................................................... 126 Install Covers, Links, and Levers....................................... 126 Ending Steps............................................................ 137 Manual Hydraulic Control Valve Repair for Lift Truck E2.2-3.5XN ................ 138 Remove...................................................................... 138 Remove Control Valve.................................................... 140 Disassemble Handles and Levers.............................................. 152 Disassemble Manual Control Valve............................................ 154 Disassemble Valve....................................................... 154 Disassemble Inlet Section............................................... 158 Disassemble Lift, Tilt, and Auxiliary Sections.......................... 158 Spool Seal Replacement...................................................... 159 Clean....................................................................... 161 Inspect..................................................................... 161 Assemble Manual Control Valve............................................... 162 Assemble Lift, Tilt, and Auxiliary Sections............................. 162 Assemble Inlet Section.................................................. 163 Assemble Valve.......................................................... 164 Assemble Handles and Levers................................................. 171 Install..................................................................... 174 Install Control Valve................................................... 174 Ending Steps............................................................ 185 E-Hydraulic Control Valve Repair for Lift Truck J1.5-2.0XNT (J30................ 185 Remove...................................................................... 185 Disassemble................................................................. 188 Clean....................................................................... 194 Inspect..................................................................... 194 Assemble.................................................................... 194 Install..................................................................... 199 E-Hydraulic Controls........................................................ 203 Replace E-Hydraulic Control Components.................................. 203 E-Hydraulic Control Valve Repair for Lift Truck E2.2-3.5XN (E45-................ 204 Remove...................................................................... 204 Initial Steps........................................................... 204 Fitting Removal for Lift Truck E2.2-3.5XN (E45-70XN) (A268)............. 204 Fitting Removal for Lift Truck J2.2-3.5XN (J45-70XN) (A276)............. 205 Electrical Disconnect and Control Valve Dismount........................ 206 Disassemble................................................................. 209 Clean....................................................................... 211 Inspect..................................................................... 212 Assemble.................................................................... 212 Install..................................................................... 218 Electrical Connect and Control Valve Mount.............................. 218 Fitting Installation for Lift Truck E2.2-3.5XN (E45-70XN) (A268)........ 221 Fitting Installation for Lift Truck J2.2-3.5XN (J45-70XN) (A276)........ 222 Ending Steps............................................................ 223 E-Hydraulic Controls........................................................ 223 Replace E-Hydraulic Control Components.................................. 224 Checks and Adjustments for Lift Truck J1.5-2.0XNT (J30-40XNT) (K................ 224 Manual Control Valve........................................................ 224 Primary Relief Valve.................................................... 224 Optional Work Port Relief Valve......................................... 225 E-Hydraulic Control Valve................................................... 225 Primary Relief Valve.................................................... 225 Optional Secondary Port Relief Valve.................................... 226 Hydraulic System Air Removal................................................ 226 Checks and Adjustments for Lift Truck E2.2-3.5XN (E45-70XN) (A26................ 227 Manual Control Valve........................................................ 227 External Leakage........................................................ 227 Primary Relief Cartridge................................................ 227 Secondary Relief Valve.................................................. 228 E-Hydraulic Control Valve................................................... 228 Primary Relief Valve.................................................... 228 Secondary Relief Valve.................................................. 229 PPRV Pilot Pressure Test................................................ 229 Hydraulic System Air Removal................................................ 231 Position Sensor and OPS Check and Adjustment.................................... 231 Position Sensor............................................................. 231 (OPS) Operator Presence Solenoid............................................ 232 Manual Control Valve Re-Calibration......................................... 232 Calibration Procedure........................................................... 232 Control Valve............................................................... 232 Torque Specifications for Lift Truck J1.5-2.0XNT (J30-40XNT) (K1................ 234 Manual Hydraulic Control Valve.............................................. 234 Manual Control Valve Handles and Levers..................................... 234 E-Hydraulic Control Valve................................................... 234 Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268................ 235 Manual Hydraulic Control Valve.............................................. 235 Manual Control Valve Handles and Levers..................................... 235 Manual Control Valve Covers................................................. 235 E-Hydraulic Control Valve................................................... 235 tables.............................................................................. 79 Table 1. Handle Options......................................................... 123 Table 2. Position Sensor Connector Pin Layout................................... 138 Table 3. Position Sensor Electrical Connector Pin Layout........................ 166 Table 4. Handle Options......................................................... 171 Table 5. Lower Solenoid Connector Pin Layout.................................... 199 Table 6. Upper Solenoid Connector Pin Layout.................................... 199 Table 7. Lower Solenoid Connector Pin Layout.................................... 218 Table 8. Upper Solenoid Connector Pin Layout.................................... 218 Table 9. Pressure Specifications................................................ 229 Table 10. Test Specifications................................................... 229 Table 11. Service Tools......................................................... 229 Table 12. Position Sensor Wiring................................................ 231 Table 13. Sensor Power Check.................................................... 231 Diagrams................................................................................ 239 toc................................................................................. 239 Diagrams........................................................................ 239 Safety Precautions Maintenance and Repair....................................... 240 Drive Axle.............................................................................. 275 toc................................................................................. 275 Drive Axle, Speed Reducer, and Differential..................................... 275 Safety Precautions Maintenance and Repair....................................... 276 General......................................................................... 279 Drive Axle Repair............................................................... 279 Remove...................................................................... 279 Disassemble................................................................. 281 Clean....................................................................... 284 Inspect..................................................................... 284 Assemble.................................................................... 284 Install..................................................................... 286 Differential Repair............................................................. 290 Remove...................................................................... 290 Differential Assembly From Center Section............................... 290 Drive Pinion, Pinion Gear, and Bearings From Center Section............. 297 Disassemble................................................................. 305 Differential Assembly, Lift Truck Models E2.2-3.5XN (E45-70XN) (........ 305 Differential Assembly, Lift Truck Models E1.6-2.0XN (E30-40XN) (........ 307 Clean and Inspect........................................................... 310 Assemble.................................................................... 311 Differential Assembly, Lift Truck Models E2.2-3.5XN (E45-70XN) (........ 311 Differential Assembly, Lift Truck Models E1.6-2.0XN (E30-40XN) (........ 315 Install..................................................................... 319 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)............... 319 Drive Pinion, Pinion Gear, and Bearings Into Center Section............. 321 Differential Assembly Into Center Section............................... 330 Ring Gear Backlash, Adjust.............................................. 335 Ring Gear, Runout Check................................................. 336 Gear Set, Tooth Contact Pattern Check................................... 336 Torque Specifications........................................................... 339 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268).............................. 339 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269).............................. 339 tables.............................................................................. 275 Table 1. Pinion Variation Numbers Examples...................................... 320 Table 2. Ring and Pinion Tooth Contact Adjustment............................... 337 Table 3. Correct Tooth Contact.................................................. 337 Table 4. Incorrect Tooth Contact................................................ 338 DTC..................................................................................... 343 toc................................................................................. 343 Diagnostic Troubleshooting Manual............................................... 343 Safety Precautions TROUBLESHOOTING PROCEDURES................................... 344 How To Use This Troubleshooting Manual.......................................... 346 General Instructions and Safety Information................................. 346 How to Use Diagnostic Troubleshooting Manual................................ 346 General Instructions........................................................ 347 Operational Diagnostic Procedures............................................... 349 Operational Checkout Procedures............................................. 351 Display Panel (DP) Check................................................ 352 Operator Presence System Check.......................................... 352 Display Backlight and Icon Power Check.................................. 353 Light Circuit Check..................................................... 353 Horn Circuit Check...................................................... 354 Backup Alarm Check (If equipped)........................................ 354 Heater Check (If equipped).............................................. 354 Brake Pedal Check....................................................... 354 Park Brake Sensor Check................................................. 355 Park Brake Check........................................................ 355 Brake and Axle Drag Check............................................... 356 Priority Flow Divider Valve Check....................................... 357 Mast Cushion Check - Free Lift Cylinder................................. 357 Lift Drift Check........................................................ 358 Lift/Tilt Mast Adjustment Check......................................... 358 Tilt Function Drift Check............................................... 359 Tilt Racking Check...................................................... 359 Tilt Function, Tilt Lock Piston......................................... 359 Mast Cushion Check - Main Lift Cylinder................................. 360 Mast Channel Check...................................................... 360 Mast Mounting Check..................................................... 360 Chain and Header Hose Adjustment Check.................................. 361 Chain Sheave Check...................................................... 361 Carriage Adjustment Check............................................... 361 Carriage Adjustment Check (Standard and Integral Side Shift)............ 361 Steering Relief Valve Low Pressure Check................................ 362 Steering Relief Valve High Pressure Check............................... 362 Traction Motor.................................................................. 363 Traction Motor.............................................................. 365 Principles of Operation ................................................ 365 Electrical System............................................................... 369 Troubleshooting Guidelines and Procedures................................... 377 Troubleshooting Guidelines.............................................. 377 Troubleshooting Procedures.............................................. 380 Troubleshooting Procedures, Identification.......................... 380 Troubleshooting Procedures, Location................................ 380 Troubleshooting Procedures, Structure............................... 380 Troubleshooting Procedures, Performance............................. 381 Troubleshooting Procedures, Final................................... 381 Diagnostic Trouble Codes................................................ 382 Wiring Reference Data....................................................... 386 Harness Assembly Data....................................................... 389 Electrical System........................................................... 417 General Description..................................................... 417 Battery............................................................. 422 Power Distribution Module (PDM)..................................... 422 Contactor....................................................... 422 Fuses........................................................... 422 Relays.......................................................... 422 Wire Harnesses.................................................. 423 Operator Interface.................................................. 423 Display......................................................... 423 Controllers......................................................... 423 Vehicle System Manager (VSM).................................... 423 Motor Controllers............................................... 424 E-Hydraulics Mini Levers Module (MLM)........................... 425 System Controlled Outputs........................................... 426 Valve Coils..................................................... 426 Lights and Backup Alarm......................................... 427 Cab options..................................................... 427 PRINCIPLES OF OPERATION, COMPONENTS..................................... 428 Power Distribution.................................................. 428 Contactor....................................................... 428 Positive Temperature Coefficient (PTC).......................... 428 Fuses........................................................... 428 Relays.......................................................... 429 Operator Interface.................................................. 430 Display......................................................... 430 Controllers......................................................... 431 Vehicle System Manager (VSM):................................... 431 Motor Controller................................................ 433 E-Hydraulics Mini Levers Module (MLM)........................... 434 PRINCIPLES OF OPERATION, SYSTEM......................................... 435 Battery (Plug-In)................................................... 435 Key ON and Operation................................................ 435 Sensors............................................................. 435 Switches............................................................ 439 Outputs............................................................. 439 Relays.......................................................... 439 Hydraulic Valve................................................. 439 Cab Devices..................................................... 441 Lights and Backup Alarm......................................... 441 12844....................................................................... 447 DTC 12844................................................................... 447 12836....................................................................... 447 DTC 12836................................................................... 447 12845....................................................................... 452 DTC 12845................................................................... 452 12837....................................................................... 452 DTC 12837................................................................... 452 12808....................................................................... 457 DTC 12808................................................................... 457 12810....................................................................... 457 DTC 12810................................................................... 457 12809....................................................................... 461 DTC 12809................................................................... 461 12811....................................................................... 461 DTC 12811................................................................... 461 12812....................................................................... 466 DTC 12812................................................................... 466 12820....................................................................... 472 DTC 12820................................................................... 472 12824....................................................................... 472 DTC 12824................................................................... 472 12821....................................................................... 476 DTC 12821................................................................... 476 12825....................................................................... 476 DTC 12825................................................................... 476 4098........................................................................ 481 DTC 4098.................................................................... 481 12852....................................................................... 485 DTC 12852................................................................... 485 12853....................................................................... 489 DTC 12853................................................................... 489 12872....................................................................... 494 DTC 12872................................................................... 494 12873....................................................................... 500 DTC 12873................................................................... 500 12832....................................................................... 505 DTC 12832................................................................... 505 12840....................................................................... 505 DTC 12840................................................................... 505 12831....................................................................... 509 DTC 12831................................................................... 509 12841....................................................................... 509 DTC 12841................................................................... 509 12800....................................................................... 514 DTC 12800................................................................... 514 12804....................................................................... 514 DTC 12804................................................................... 514 12801....................................................................... 518 DTC 12801................................................................... 518 12805....................................................................... 518 DTC 12805................................................................... 518 12816....................................................................... 523 DTC 12816................................................................... 523 12819....................................................................... 527 DTC 12819................................................................... 527 12545....................................................................... 532 DTC 12545................................................................... 532 12546....................................................................... 532 DTC 12546................................................................... 532 13056....................................................................... 539 DTC 13056................................................................... 539 13057....................................................................... 539 DTC 13057................................................................... 539 12856....................................................................... 547 DTC 12856................................................................... 547 12860....................................................................... 547 DTC 12860................................................................... 547 12864....................................................................... 547 DTC 12864................................................................... 547 12868....................................................................... 547 DTC 12868................................................................... 547 12857....................................................................... 551 DTC 12857................................................................... 551 12861....................................................................... 551 DTC 12861................................................................... 551 12865....................................................................... 551 DTC 12865................................................................... 551 12869....................................................................... 551 DTC 12869................................................................... 551 12332....................................................................... 556 DTC 12332................................................................... 556 8960........................................................................ 561 DTC 8960.................................................................... 561 8964........................................................................ 561 DTC 8964.................................................................... 561 8968........................................................................ 561 DTC 8968.................................................................... 561 8972........................................................................ 561 DTC 8972.................................................................... 561 8978........................................................................ 561 DTC 8978.................................................................... 561 8980........................................................................ 561 DTC 8980.................................................................... 561 8984........................................................................ 561 DTC 8984.................................................................... 561 8988........................................................................ 561 DTC 8988.................................................................... 561 13312....................................................................... 566 DTC 13312................................................................... 566 13316....................................................................... 566 DTC 13316................................................................... 566 13320....................................................................... 566 DTC 13320................................................................... 566 13324....................................................................... 566 DTC 13324................................................................... 566 13328....................................................................... 566 DTC 13328................................................................... 566 13332....................................................................... 566 DTC 13332................................................................... 566 13336....................................................................... 566 DTC 13336................................................................... 566 13340....................................................................... 566 DTC 13340................................................................... 566 33025....................................................................... 571 DTC 33025................................................................... 571 33026....................................................................... 571 DTC 33026................................................................... 571 33027....................................................................... 571 DTC 33027................................................................... 571 33029....................................................................... 571 DTC 33029................................................................... 571 33034....................................................................... 571 DTC 33034................................................................... 571 33035....................................................................... 571 DTC 33035................................................................... 571 33036....................................................................... 571 DTC 33036................................................................... 571 33037....................................................................... 571 DTC 33037................................................................... 571 33038....................................................................... 571 DTC 33038................................................................... 571 33057....................................................................... 571 DTC 33057................................................................... 571 33025....................................................................... 585 DTC 33025................................................................... 585 33026....................................................................... 585 DTC 33026................................................................... 585 33027....................................................................... 585 DTC 33027................................................................... 585 33029....................................................................... 585 DTC 33029................................................................... 585 33034....................................................................... 585 DTC 33034................................................................... 585 33035....................................................................... 585 DTC 33035................................................................... 585 33036....................................................................... 585 DTC 33036................................................................... 585 33037....................................................................... 585 DTC 33037................................................................... 585 33038....................................................................... 585 DTC 33038................................................................... 585 33057....................................................................... 585 DTC 33057................................................................... 585 33025....................................................................... 600 DTC 33025................................................................... 600 33026....................................................................... 600 DTC 33026................................................................... 600 33027....................................................................... 600 DTC 33027................................................................... 600 33029....................................................................... 600 DTC 33029................................................................... 600 33034....................................................................... 600 DTC 33034................................................................... 600 33035....................................................................... 600 DTC 33035................................................................... 600 33036....................................................................... 600 DTC 33036................................................................... 600 33037....................................................................... 600 DTC 33037................................................................... 600 33038....................................................................... 600 DTC 33038................................................................... 600 33057....................................................................... 600 DTC 33057................................................................... 600 21830....................................................................... 613 DTC 21830................................................................... 613 21834....................................................................... 613 DTC 21834................................................................... 613 21835....................................................................... 613 DTC 21835................................................................... 613 21836....................................................................... 613 DTC 21836................................................................... 613 21837....................................................................... 613 DTC 21837................................................................... 613 25344....................................................................... 613 DTC 25344................................................................... 613 4112........................................................................ 619 DTC 4112.................................................................... 619 4113........................................................................ 619 DTC 4113.................................................................... 619 4114........................................................................ 619 DTC 4114.................................................................... 619 4115........................................................................ 619 DTC 4115.................................................................... 619 4116........................................................................ 619 DTC 4116.................................................................... 619 13060....................................................................... 622 DTC 13060................................................................... 622 13061....................................................................... 622 DTC 13061................................................................... 622 22032....................................................................... 631 DTC 22032................................................................... 631 22033....................................................................... 631 DTC 22033................................................................... 631 33056....................................................................... 631 DTC 33056................................................................... 631 33057....................................................................... 631 DTC 33057................................................................... 631 8704........................................................................ 631 DTC 8704.................................................................... 631 12934....................................................................... 631 DTC 12934................................................................... 631 12935....................................................................... 631 DTC 12935................................................................... 631 8705........................................................................ 631 DTC 8705.................................................................... 631 12936....................................................................... 631 DTC 12936................................................................... 631 12937....................................................................... 631 DTC 12937................................................................... 631 22528....................................................................... 631 DTC 22528................................................................... 631 22529....................................................................... 631 DTC 22529................................................................... 631 22530....................................................................... 631 DTC 22530................................................................... 631 22531....................................................................... 631 DTC 22531................................................................... 631 22532....................................................................... 631 DTC 22532................................................................... 631 22533....................................................................... 631 DTC 22533................................................................... 631 22534....................................................................... 631 DTC 22534................................................................... 631 22535....................................................................... 631 DTC 22535................................................................... 631 22536....................................................................... 631 DTC 22536................................................................... 631 22537....................................................................... 631 DTC 22537................................................................... 631 22538....................................................................... 631 DTC 22538................................................................... 631 22539....................................................................... 631 DTC 22539................................................................... 631 22540....................................................................... 631 DTC 22540................................................................... 631 22541....................................................................... 631 DTC 22541................................................................... 631 9041........................................................................ 637 DTC 9041.................................................................... 637 12940....................................................................... 637 DTC 12940................................................................... 637 12941....................................................................... 637 DTC 12941................................................................... 637 21760....................................................................... 649 DTC 21760................................................................... 649 21761....................................................................... 649 DTC 21761................................................................... 649 21762....................................................................... 649 DTC 21762................................................................... 649 21764....................................................................... 649 DTC 21764................................................................... 649 21766....................................................................... 649 DTC 21766................................................................... 649 21792....................................................................... 649 DTC 21792................................................................... 649 12928....................................................................... 654 DTC 12928................................................................... 654 12929....................................................................... 654 DTC 12929................................................................... 654 9040........................................................................ 654 DTC 9040.................................................................... 654 12938....................................................................... 654 DTC 12938................................................................... 654 12939....................................................................... 654 DTC 12939................................................................... 654 9000........................................................................ 660 DTC 9000.................................................................... 660 9004........................................................................ 660 DTC 9004.................................................................... 660 9008........................................................................ 660 DTC 9008.................................................................... 660 9012........................................................................ 660 DTC 9012.................................................................... 660 9016........................................................................ 660 DTC 9016.................................................................... 660 9020........................................................................ 660 DTC 9020.................................................................... 660 9026........................................................................ 660 DTC 9026.................................................................... 660 9028........................................................................ 660 DTC 9028.................................................................... 660 9032........................................................................ 660 DTC 9032.................................................................... 660 9036........................................................................ 660 DTC 9036.................................................................... 660 13352....................................................................... 665 DTC 13352................................................................... 665 13356....................................................................... 665 DTC 13356................................................................... 665 13360....................................................................... 665 DTC 13360................................................................... 665 13364....................................................................... 665 DTC 13364................................................................... 665 13368....................................................................... 665 DTC 13368................................................................... 665 13372....................................................................... 665 DTC 13372................................................................... 665 13376....................................................................... 665 DTC 13376................................................................... 665 13380....................................................................... 665 DTC 13380................................................................... 665 13384....................................................................... 665 DTC 13384................................................................... 665 13388....................................................................... 665 DTC 13388................................................................... 665 21569....................................................................... 671 DTC 21569................................................................... 671 21570....................................................................... 671 DTC 21570................................................................... 671 12592....................................................................... 682 DTC 12592................................................................... 682 29456....................................................................... 689 DTC 29456................................................................... 689 25104....................................................................... 700 DTC 25104................................................................... 700 29456....................................................................... 700 DTC 29456................................................................... 700 8786........................................................................ 712 DTC 8786.................................................................... 712 12834....................................................................... 712 DTC 12834................................................................... 712 12835....................................................................... 712 DTC 12835................................................................... 712 65513....................................................................... 721 DTC 65513................................................................... 721 12576....................................................................... 729 DTC 12576................................................................... 729 65280....................................................................... 739 DTC 65280................................................................... 739 8976........................................................................ 746 DTC 8976.................................................................... 746 9024........................................................................ 746 DTC 9024.................................................................... 746 65527....................................................................... 757 DTC 65527................................................................... 757 33024....................................................................... 764 DTC 33024................................................................... 764 12802....................................................................... 772 DTC 12802................................................................... 772 12806....................................................................... 779 DTC 12806................................................................... 779 12807....................................................................... 783 DTC 12807................................................................... 783 16912....................................................................... 791 DTC 16912................................................................... 791 17168....................................................................... 791 DTC 17168................................................................... 791 25105....................................................................... 791 DTC 25105................................................................... 791 21008....................................................................... 804 DTC 21008................................................................... 804 4096........................................................................ 810 DTC 4096.................................................................... 810 20753....................................................................... 815 DTC 20753................................................................... 815 20755....................................................................... 815 DTC 20755................................................................... 815 12576....................................................................... 821 DTC 12576................................................................... 821 12817....................................................................... 821 DTC 12817................................................................... 821 12818....................................................................... 821 DTC 12818................................................................... 821 12833....................................................................... 821 DTC 12833................................................................... 821 21520....................................................................... 839 DTC 21520................................................................... 839 None........................................................................ 851 DTC None.................................................................... 851 None........................................................................ 860 DTC None.................................................................... 860 None........................................................................ 873 DTC None.................................................................... 873 Horn Failure................................................................ 884 Icon Glossary............................................................... 889 Introduction to Icons................................................... 889 Drive Axle/Unit................................................................. 897 Drive Axle J1.5-2.0XNT (J30-40XNT) (K160) J1.6-2.0XN (A935)................. 899 Description............................................................. 899 Principles of Operation................................................. 899 Drive Units......................................................... 899 Brakes.............................................................. 899 Drive Axle E2.2-3.5XN (E40-70XN) (A268) E1.6-2.0XN E30-40XN (A26............ 900 Description............................................................. 900 Dry Brake System........................................................ 902 General............................................................. 902 Master Cylinder..................................................... 902 Parking Brake....................................................... 902 Automatic Park Brake................................................ 902 MONOTROL® Pedal......................................................... 902 Description......................................................... 902 Principles of Operation............................................. 903 One Drive Wheel Will Not Move............................................... 905 Noise During Operation That Is Not Normal................................... 906 Oil Leaks................................................................... 908 Park Brake Does Not Operate Properly........................................ 909 Hydraulic Systems............................................................... 911 Manual Hydraulic Main Control Valve......................................... 915 Description............................................................. 915 Manual Hydraulic Control System......................................... 915 General Description (Open Center Valve)................................. 917 CONSTRUCTION........................................................ 917 VALVE TYPE.......................................................... 917 Features and Operation.................................................. 918 INLET ASSEMBLY...................................................... 918 Construction and Purpose........................................ 918 Porting......................................................... 918 Priority Steer.................................................. 918 Relief Cartridge................................................ 919 LIFT SECTION........................................................ 920 Construction.................................................... 920 Purpose......................................................... 920 Load Check...................................................... 921 Operator Presence Solenoid...................................... 921 Position Sensor Assembly........................................ 922 Mast Lowering Cartridge......................................... 923 TILT SECTION........................................................ 924 Construction.................................................... 924 Purpose......................................................... 924 AUXILIARY AND DUAL AUXILIARY SECTION................................ 925 Construction.................................................... 925 Purpose......................................................... 925 OUTLET COVER SECTION................................................ 926 Construction and Purpose........................................ 926 General Description (Closed Center Valve)............................... 927 CONSTRUCTION........................................................ 927 VALVE TYPE.......................................................... 927 Features and Operation.................................................. 928 INLET ASSEMBLY...................................................... 928 Construction and Purpose........................................ 928 Porting......................................................... 928 Priority Steer.................................................. 928 Unloading Spool and Relief Cartridge............................ 929 LIFT SECTION........................................................ 930 Purpose......................................................... 930 Operation - Main Spool.......................................... 930 Load Check...................................................... 931 Operator Presence Solenoid...................................... 932 Position Sensor................................................. 932 Mast Lowering Cartridge......................................... 933 TILT SECTION........................................................ 933 Construction and Purpose........................................ 933 Operation....................................................... 933 Main Spool with Tilt-Lock....................................... 934 AUXILIARY AND DUAL AUXILIARY SECTIONS............................... 935 Construction and Purpose........................................ 935 Operation....................................................... 936 E-Hydraulic Main Control Valve.............................................. 936 Electro-Hydraulic Control System........................................ 936 General Valve Description............................................... 938 Construction........................................................ 938 Valve Type.......................................................... 938 Features and Operation.................................................. 939 Inlet Section....................................................... 939 Construction and Purpose........................................ 939 Porting......................................................... 939 Priority Steer.................................................. 939 Unloading Spool and Relief Cartridge............................ 940 Pilot Cartridge................................................. 941 Lift Section........................................................ 941 Construction and Purpose........................................ 941 Operation - Main Spool.......................................... 941 Load Check...................................................... 943 Mast Lowering Cartridge......................................... 943 Electro-Hydraulic (EH) Solenoid................................. 944 Tilt Section........................................................ 944 Construction and Purpose........................................ 944 Operation....................................................... 944 Main Spool...................................................... 945 Spacer Sections..................................................... 945 Construction and Purpose........................................ 945 Auxiliary and Dual Auxiliary Sections............................... 946 Construction and Purpose........................................ 946 Operation....................................................... 946 Steering System............................................................. 947 Description............................................................. 947 Accumulator, Piston................................................. 948 Priority Steer (E-Hydraulic Control Valve).......................... 948 Priority Steer (Manual Hydraulics Open Center Control Valve)........ 949 Priority Steer (Manual Hydraulics Closed Center Control Valve)...... 950 Steering Control Unit (SCU) Operation................................... 951 Abnormal Hydraulic Noise and/or Vibration................................... 953 Abnormal Smell/Discoloration/Foaming of Oil................................. 957 Cycle Times Too Fast - Fast Actuation (E-Valve)............................. 958 Jump/Delay In Lift or Lower Activation After Moving MLM (E-Valve............ 960 Jump/Delay In Auxiliary Function Actuation After Moving MLM (E-V............ 962 Jump/Delay In Tilt Forward or Back Actuation (E-Valve)...................... 964 Forks Drop Slightly Before Lifting (E-Valve)................................ 965 Forks Lower Without Command (E-Valve)....................................... 966 Forks Raise or Actuate Without Command (E-Valve)............................ 967 Intermittent Activation (E-Valve) While Commanding Function................. 968 Forks Tilt Forward Without Command (E-Valve)................................ 969 Lift/Lower Function Maximum Speed Too Slow (E-Valve)........................ 972 Lift Function Will Not Move With MLM Movement (E-Valve)..................... 975 Lift/Lower Continues To Move For Awhile After MLM Is Released (E............ 978 Lift/Lower/Auxiliary Function Suddenly Jumps In Middle of Stroke............ 979 Lower Function Will Not Move With MLM Movement (E-Valve).................... 980 Poor Metering on Lift or Lower Functions (E-Valve).......................... 981 Auxiliary Function Continues to Move for Awhile After MLM Is Rel............ 984 Auxiliary Function Maximum Speed Too Slow (E-Valve)......................... 985 Auxiliary Function or Tilt Back Moves Without Command (E-Valve)............. 988 Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move ............ 989 Tilt Forward or Tilt Back Function Continues to Move for Awhile ............ 993 Tilt Forward or Tilt Back Will Not Move With MLM Movement (E-Val............ 994 Too Much MLM Movement (Deadband) to Start Function Moving (E-Val............ 996 Wrong Actuation Operates or Actuation is Backward (E-Valve)................. 997 Actuation Exhibits Slight Movement in Opposite Direction Before ............ 998 Auxiliary Function is Slow or Does Not Function (Manual Valve).............. 999 Cycle Times Too Fast - Fast Actuation (Manual Valve)........................1002 Function Continues to Activate After Returning to Neutral...................1003 Lift Function Is Slow or Does Not Function (Manual Valve)...................1004 Tilt Back Function Will Not Operate (Manual Valve)..........................1007 Tilt Forward or Tilt Back Will Not Function When Activated (Manu............1008 No Steering (All Other Hydraulic Functions OK)..............................1009 Steering Is Slow or Difficult...............................................1011 Steering Operation Is Not Smooth............................................1013 Steering Wheel End Lock Position Cannot Be Felt by Operator.................1015 Steering Wheel Turns By Itself or Does Not Return To Neutral................1016 Steering Wheel Turns the Tires in the Wrong Direction.......................1018 Actuations Do Not Act Simultaneously........................................1019 Oil Leaking/Component Life Too Short........................................1020 Abnormal Steer Axle Noise...................................................1023 Abnormal Steering Wheel Vibration...........................................1025 Back Lash/Kick Back in Steering Wheel.......................................1026 Hydraulic Warm-up Procedure.................................................1029 Primary Relief Valve Test and Adjustment....................................1030 Secondary Relief Valve Test and Adjustment..................................1032 Hydraulic Pump Flow Test....................................................1037 Main Control Valve LS Leakage Test (E-Valve)................................1039 Main Control Valve Unloader Margin Test.....................................1040 E-Hydraulic Valve Leakage Test..............................................1042 Steering Relief Pressure Test and Adjustment................................1046 Steering Control Unit LS Pressure Test......................................1049 Lift Cylinder Leakage Test..................................................1051 Tilt Cylinder Leakage Test..................................................1053 Steering Cylinder Leakage Test..............................................1056 Operators Station...............................................................1059 Operator Station General Description and Principles of Operation............1061 General Description and Location........................................1061 Display Panel...............................................................1063 General Description.....................................................1063 Common Display Panel Features.......................................1063 Premium Display Panel...............................................1063 Display Panel.......................................................1064 LCD Screen and Warning and Indicator Lights.........................1066 Programming - Menus.........................................................1067 Menu....................................................................1067 Operator Cycle Main Menu............................................1067 Supervisor/Service Cycle Main Menu..................................1067 Activity Log....................................................1067 Calibration.....................................................1067 Diagnostic......................................................1067 Truck Set-Up....................................................1068 Truck Status....................................................1068 Display Adjustments.............................................1068 Display Menu Flowchart......................................................1068 Display Menu Flowchart..................................................1068 Manual Hydraulic Control Levers.............................................1090 General Description.....................................................1090 System Components.......................................................1090 Lift/Lower..........................................................1090 Tilt................................................................1090 Auxiliary 1.........................................................1090 Auxiliary 2.........................................................1091 Emergency Disconnect Switch.........................................1091 E-Hydraulic System Interface................................................1092 General Description to E-Hydraulic System Interface.....................1092 Lift/Lower..........................................................1092 Tilt................................................................1092 Return-To-Set-Tilt (RTST).......................................1093 Auxiliary 1.........................................................1093 Auxiliary 2.........................................................1093 Emergency Disconnect Switch.........................................1094 Lighting Control............................................................1094 General Description.....................................................1094 Front Work Lights...................................................1094 Front Marker Lights.................................................1094 Front/Rear Turn Signal Lights.......................................1094 Rear Tail Lights....................................................1094 Rear Work Light.....................................................1095 Rear Backup Lights..................................................1095 Rear Stop Lights....................................................1095 Strobe Light........................................................1095 Dome Light..........................................................1095 Cab Panels..................................................................1096 General Description.....................................................1096 Covers and Floor Plates.............................................1096 Hood and Seat.......................................................1096 Hood............................................................1096 Seat............................................................1096 Cab Heating System..................................................1096 Control Panel...................................................1097 Heater Core.....................................................1097 Heater Fan......................................................1097 Wiper/Washer System.................................................1097 Front End (Mast) and Chassis....................................................1099 Front End, Mast.............................................................1101 Description.............................................................1101 Carriages...................................................................1102 Description.............................................................1102 Principles of Operation.................................................1102 Integral Sideshift Carriage.........................................1102 Mast Mounts.................................................................1104 Description.............................................................1104 Principles of Operation.................................................1104 Two-Stage Full Free-Lift (FFL) Mast.........................................1104 Description.............................................................1104 Principles of Operation.................................................1105 Two-Stage Limited Free-Lift (LFL) Mast......................................1106 Description.............................................................1106 Principles of Operation.................................................1107 Three-Stage Full Free-Lift (FFL) Mast.......................................1108 Description.............................................................1108 Principles of Operation.................................................1109 Four-Stage Full Free-Lift (FFL) Mast........................................1110 Description.............................................................1110 Principles of Operation.................................................1112 Cylinder Cushion During Lifting Sequence....................................1114 Description.............................................................1114 Principles of Operation.................................................1114 Cylinder Cushion During Lowering Sequence...................................1115 Description.............................................................1115 Principles of Operation.................................................1115 Tilt and Sideshift Cylinders................................................1116 Description.............................................................1116 Tilt Cylinder.......................................................1116 Sideshift Cylinder..................................................1116 Lowering Control Valves.....................................................1116 Description.............................................................1116 Principles of Operation.................................................1116 Chassis.....................................................................1118 Description.............................................................1118 Overhead Guard .....................................................1118 Counterweight.......................................................1118 Abnormal Channel Wear.......................................................1119 Abnormal Hose Wear..........................................................1121 Abnormal Mast Noise.........................................................1123 Body Panels Making Noise....................................................1127 External Leakage From Free-Lift or Main Lift Cylinders......................1128 FFL Mast Banging During Phasing.............................................1129 High Tire Wear - Drive Axle.................................................1131 High Tire Wear - Steer Axle.................................................1132 Hoses Not Tracking Correctly................................................1134 Integral Sideshift Moving Too Fast..........................................1135 Integral Sideshift Not Moving or Slow.......................................1136 Mast is Loose...............................................................1139 Mast Lift Chains Are Loose..................................................1141 Mast or Carriage Binding....................................................1142 Mast/Carriage Bounces or is Spongy..........................................1145 Misphasing of Full Free-Lift Mast...........................................1146 Overhead Guard Loose or Damaged.............................................1148 Racking During Lift.........................................................1149 Racking During Tilt.........................................................1151 Truck Feels Unstable........................................................1152 Truck Wanders, Does Not Track Straight or Steer Well........................1153 Wheel Studs Breaking........................................................1154 Supplementary Data..............................................................1155 Abbreviations and Acronyms..................................................1157 Fault Mode Indicator (FMI) Reference List...................................1163 tables.............................................................................. 343 Table 9030-03-1. Circuit Group Identification................................... 386 Table 9030-03-2. Hyster Wiring Color Codes...................................... 387 Table 9030-10-1. Silicon Temperature Sensors.................................... 437 Table 9030-20-1. Main Schematic................................................. 573 Table 9030-20-2. Device Connectors.............................................. 574 Table 9030-20-3. Main Schematic................................................. 587 Table 9030-20-4. Device Connectors.............................................. 588 Table 9030-20-5. Main Schematic................................................. 602 Table 9030-20-6. Device Connectors.............................................. 603 Table 9030-20-7. Main Schematic................................................. 615 Table 9030-20-8. Device Connectors.............................................. 625 Table 9030-20-9. Display Internal Failure Fault DTCs............................ 632 Table 9030-20-10. CBB Temperature Control Chart Table........................... 792 Table 9030-20-11. DBB Temperature Control Chart Table........................... 793 Table 9050-43-1. Test Specifications............................................1029 Table 9050-43-2. Service Tools..................................................1029 Table 9050-43-3. Service Tools..................................................1030 Table 9050-43-4. Test Specifications............................................1030 Table 9050-43-5. Test Specifications for Lift Trucks J1.5-2.0XNT................1032 Table 9050-43-6. Test Specifications for Lift Trucks E2.2-3.5XN ................1033 Table 9050-43-7. Service Tools..................................................1033 Table 9050-43-8. Test Specifications............................................1037 Table 9050-43-9. Service Tools..................................................1037 Table 9050-43-10. Test Specifications...........................................1039 Table 9050-43-11. Test Specifications...........................................1040 Table 9050-43-12. Service Tools.................................................1040 Table 9050-43-13. Test Specifications...........................................1043 Table 9050-43-14. Test Specifications...........................................1046 Table 9050-43-15. Service Tools.................................................1046 Table 9050-43-16. Test Specifications...........................................1049 Table 9050-43-17. Service Tools.................................................1049 Table 9050-43-18. Test Specifications...........................................1051 Table 9050-43-19. Service Tools.................................................1051 Table 9050-43-20. Test Specifications...........................................1053 Table 9050-43-21. Service Tools.................................................1053 Table 9050-43-22. Test Specifications...........................................1056 Table 9050-43-23. Service Tools.................................................1056 Table 9060-10-1. Display Panel..................................................1064 Table 9060-10-2. Activity Logs..................................................1071 Table 9060-10-3. Calibration....................................................1073 Table 9060-10-4. Diagnostics....................................................1075 Table 9060-10-5. Truck-Setup....................................................1079 Table 9060-10-6. Truck Status...................................................1085 Table 9060-10-7. Display Adjustments............................................1088 Table 9080-50-1. Abbreviations and Acronyms.....................................1157 Table 9080-70-1. FMI............................................................1163 Electrical System.......................................................................1167 toc.................................................................................1167 Electrical System...............................................................1167 Safety Precautions Maintenance and Repair.......................................1168 General.........................................................................1175 Discharging the Capacitors..................................................1176 Display Panel and Key or Keyless Switch Replacement.............................1177 Display Panel, Replace......................................................1177 Remove..................................................................1177 Install.................................................................1178 Electronic and Manual Hydraulic Controls........................................1180 General.....................................................................1180 Manual Hydraulic Controls...................................................1180 Upper Front Cover.......................................................1180 Direction Control Switch................................................1182 Remove..............................................................1182 Install.............................................................1182 Clamp Button............................................................1186 Remove..............................................................1186 Install.............................................................1186 Emergency Disconnect Switch.............................................1186 Remove..............................................................1186 Install.............................................................1187 E-Hydraulic Controls - Test.................................................1188 Mini-Levers.............................................................1188 Full Stroke Test........................................................1188 Function Returns to Neutral Test........................................1188 Push Button Switch......................................................1188 E-Hydraulic Controls........................................................1188 Mini-levers, Remove and Install.........................................1189 Armrest Assembly........................................................1190 Remove..............................................................1190 Install.............................................................1191 Horn Button.............................................................1192 Remove..............................................................1192 Install.............................................................1192 Direction Control Switch................................................1193 Remove..............................................................1193 Install.............................................................1193 Emergency Disconnect Switch.............................................1194 Remove..............................................................1194 Install.............................................................1194 Momentary Switches and Function Selection Button........................1195 Remove..............................................................1195 Install.............................................................1196 Sensors and Switches............................................................1197 General.....................................................................1197 Steering Axle Sensor........................................................1197 Remove..................................................................1197 Install.................................................................1199 Hydraulic Motor Speed Sensor................................................1200 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................1200 Remove..............................................................1200 Install.............................................................1200 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1203 Remove..............................................................1203 Install.............................................................1203 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................1205 Remove..............................................................1205 Install.............................................................1205 Hydraulic Motor Temperature Sensor..........................................1205 Hydraulic Tank Level Sensor.................................................1206 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1206 Remove..............................................................1206 Install.............................................................1206 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........1207 Remove..............................................................1207 Install.............................................................1207 Hydraulic Filter Sensor.....................................................1208 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1208 Remove..............................................................1208 Install.............................................................1208 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........1208 Remove..............................................................1208 Install.............................................................1209 Hydraulic Oil Temperature Sensor............................................1210 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1210 Remove..............................................................1210 Install.............................................................1210 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................1210 Remove..............................................................1210 Install.............................................................1210 Traction Speed Sensor.......................................................1211 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1211 Remove..............................................................1211 Install.............................................................1212 E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)...........1212 Remove..............................................................1212 Install.............................................................1212 Traction Motor Temperature Sensor...........................................1214 Tilt Position Sensor E2.2-3.5XN (E45-70XN) (A268) and J2.2-3.5XN............1214 Remove..................................................................1214 Install.................................................................1215 Tilt Position Sensor E1.6-2.0XN (E30-40XN) (A269)...........................1216 Remove..................................................................1216 Install.................................................................1216 Low Level Brake Fluid Switch................................................1216 Remove..................................................................1216 Install.................................................................1217 Service Brake Pressure Sensor...............................................1219 Remove..................................................................1219 Install.................................................................1219 Accelerator Pedal Position Sensor...........................................1219 Remove..................................................................1219 Install.................................................................1219 Seat Sensor (Operator Presence System)......................................1221 Non-Suspension Seat.....................................................1221 Remove..............................................................1221 Install.............................................................1222 Full Suspension and Swivel Seats........................................1222 Remove..............................................................1222 Install.............................................................1222 Steering Direction Sensor...................................................1223 Remove..................................................................1223 Install.................................................................1223 Load Weight Sensor..........................................................1224 Remove..................................................................1224 Install.................................................................1225 Battery Gate Switch.........................................................1225 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........1226 Remove..............................................................1226 Install.............................................................1226 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1228 Remove..............................................................1228 Install.............................................................1228 Horn Switch.................................................................1229 Fixed Steering Column...................................................1229 Remove..............................................................1229 Install.............................................................1229 Telescopic Steering Column..............................................1230 Remove..............................................................1230 Install.............................................................1231 Impact Sensor...............................................................1231 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1231 Remove..............................................................1231 Install.............................................................1232 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........1233 Remove..............................................................1233 Install.............................................................1234 Rear and Hood Horn Button Switches..........................................1234 Rear Horn Button Switch.................................................1234 Remove..............................................................1234 Install.............................................................1235 Hood Horn Button Switch.................................................1235 Remove..............................................................1235 Install.............................................................1235 Motor Controllers Replacement...................................................1237 General.....................................................................1237 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E............1241 Traction Motor and Hydraulic Pump and Motor Controllers.................1241 Remove..............................................................1241 Install.............................................................1241 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..............................1244 Hydraulic Pump and Motor Controller.....................................1244 Remove..............................................................1244 Install.............................................................1244 Traction Motor Controllers..............................................1246 Remove..............................................................1246 Install.............................................................1246 Line Contactor..............................................................1249 Remove..................................................................1249 Install.................................................................1249 Fans........................................................................1251 Remove..................................................................1251 Install.................................................................1252 Vehicle System Manager..........................................................1253 General.....................................................................1253 Remove......................................................................1253 Install.....................................................................1253 Programming a New VSM and/or Display Panel..................................1255 General.................................................................1255 PC Service Tool Software....................................................1255 Fuses and Relays................................................................1256 Fuses.......................................................................1256 Relays......................................................................1259 Backup Alarm....................................................................1262 Battery Connection..............................................................1264 Inspect.....................................................................1264 Replacing Cables............................................................1264 Cab Heater......................................................................1266 Lights..........................................................................1266 General.....................................................................1266 Work Lights (Front and Rear)................................................1269 Halogen Bulb Lights.....................................................1269 Remove..............................................................1269 Install.............................................................1269 LED Lights..............................................................1270 Remove..............................................................1270 Install.............................................................1270 Strobe Light................................................................1270 Remove..................................................................1270 Install.................................................................1270 LED Tail, Backup, and Brake Lights..........................................1271 Remove..................................................................1271 Install.................................................................1271 Front Marker/Turn Signal Lights.............................................1272 Remove..................................................................1272 Install.................................................................1272 Dome Light..................................................................1272 Remove..................................................................1272 Install.................................................................1272 Converter...................................................................1273 Remove..................................................................1273 Install.................................................................1273 Frame...................................................................................1279 toc.................................................................................1279 Frame...........................................................................1279 Safety Precautions Maintenance and Repair.......................................1280 General.........................................................................1283 General.....................................................................1283 Frame.......................................................................1283 Discharging the Capacitors..................................................1287 Overhead Guard Replacement for Lift Trucks E2.2-3.5XN (E45-70XN)................1288 Remove......................................................................1288 Install.....................................................................1290 Overhead Guard Replacement for Lift Truck Models J2.2-3.5XN (J45................1291 Remove......................................................................1291 Install.....................................................................1293 Battery Restraint and Seat Assembly Repair......................................1294 Operator Restraint System and Seat Assembly.................................1299 Operator Restraint System...............................................1299 Emergency Locking Retractor (ELR)...................................1301 Armrest Assembly Repair.................................................1302 Remove..............................................................1302 Disassemble.........................................................1304 Clean...............................................................1305 Inspect.............................................................1305 Assemble............................................................1305 Install.............................................................1306 Hood and Seat Latches...................................................1306 Hood and Seat Assembly Replacement for Lift Truck Models E2.2-3.................1307 General.....................................................................1307 Remove......................................................................1311 Install.....................................................................1316 Ground Test.................................................................1317 Hood and Seat Assembly Replacement for Lift Truck Models J2.2-3.................1317 General.....................................................................1317 Opening and Closing the Hood............................................1320 Remove......................................................................1321 Install.....................................................................1323 Ground Test.................................................................1324 Master Cylinder Repair and Adjustment for Lift Truck E2.2-3.5XN ................1325 Master Cylinder Repair and Adjustment for Lift Truck J2.2-3.5XN ................1325 Remove......................................................................1325 Disassemble.................................................................1325 Clean.......................................................................1328 Inspect.....................................................................1328 Assemble....................................................................1328 Bench Bleed Master Cylinder.................................................1328 Install and Adjust..........................................................1328 Brake Pedal Components for Lift Trucks E2.2-3.5XN (E45-70XN) (A2................1329 Brake Pedal Components for Lift Truck J2.2-3.5XN (J45-70XN) (A27................1329 Remove......................................................................1329 Disassemble.................................................................1331 Inspect.....................................................................1331 Assemble....................................................................1331 Install.....................................................................1332 Pedal Adjust................................................................1332 Brake System Air Removal for Lift Truck J2.2-3.5XN (J45-70XN) (A................1333 Brake System Air Removal....................................................1333 Using Pressure Bleed System.................................................1333 Using Brake Pedal Pressure..................................................1333 Brake System Air Removal for Lift Trucks E2.2-3.5XN (E45-70XN) (................1333 Counterweight Replacement for Lift Trucks E2.2-3.5XN (E45-70XN) ................1334 Remove......................................................................1335 Install.....................................................................1336 Counterweight Replacement for Lift Trucks J2.2-3.5XN (J45-70XN) ................1336 Remove......................................................................1338 Install.....................................................................1338 Traction Motor Replacement for Lift Trucks E2.2-3.5XN (E45-70XN)................1340 Remove......................................................................1340 Install.....................................................................1345 Traction Motor Repair or Replacement for Lift Truck J2.2-3.5XN (................1346 Hydraulic Tank Inspection.......................................................1346 Inspect.....................................................................1346 Clean.......................................................................1347 Painting Instructions...........................................................1349 Safety Label Replacement........................................................1351 Battery Specifications..........................................................1358 Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268................1360 Overhead Guard..............................................................1360 Counterweight...............................................................1360 Traction Motor..............................................................1360 Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276................1360 Overhead Guard..............................................................1360 Counterweight...............................................................1360 tables..............................................................................1279 Table 1. Counterweights for Lift Truck E2.2-3.5XN (E45-70XN) (A2................1335 Table 2. Counterweights for Lift Truck E1.6-2.0XN (E30-40XN) (A2................1335 Table 3. Counterweights for Lift Truck J2.2-3.5XN (J45-70XN) (A2................1338 Table 4. E2.2-3.5XN (E45-70XN) (A268) Model Trucks..............................1358 Table 5. J2.2-3.5XN (J45-70XN) (A276) Model Trucks..............................1359 Table 6. E1.6-2.0XN (E30-40XN) (A269) Model Trucks..............................1359 Hydraulics..............................................................................1363 toc.................................................................................1363 Hydraulic System................................................................1363 Safety Precautions Maintenance and Repair.......................................1364 General.........................................................................1367 Discharging the Capacitors..................................................1367 Hydraulic Pump and Motor........................................................1368 Remove......................................................................1368 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................1368 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................1371 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1374 Disassemble.................................................................1377 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........1377 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1379 Inspect.....................................................................1379 Clean.......................................................................1379 Assemble....................................................................1381 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........1381 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1381 Install.....................................................................1381 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................1381 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................1382 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1383 Hydraulic Tank for Lift Truck ..................................................1384 Remove......................................................................1384 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................1384 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................1387 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1389 Disassemble.................................................................1390 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................1390 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................1391 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1392 Clean.......................................................................1394 Steam Method............................................................1394 Chemical Method.........................................................1394 Inspect.....................................................................1394 Small Leaks, Repair.....................................................1395 Large Leaks, Repair.....................................................1395 Additional Methods for Metal Tank Repair................................1395 Assemble....................................................................1395 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................1395 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................1396 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1396 Install.....................................................................1397 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................1397 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................1397 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1397 Hydraulic Filter Replacement................................................1398 Breather Clean and Inspect..................................................1399 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........1399 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1402 Add Hydraulic Oil...........................................................1402 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................1402 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................1404 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................1404 Steer Accumulator Replacement...................................................1405 Remove......................................................................1405 Install.....................................................................1407 Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268)......................1408 Tank Capacity...............................................................1408 Specifications for Lift Truck E1.6-2.0XN (E30-40XN) (A269)......................1408 Tank Capacity...............................................................1408 Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276)......................1409 Tank Capacity...............................................................1409 Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268................1409 Hydraulic Pump and Motor....................................................1409 Hydraulic Tank..............................................................1409 Torque Specifications for Lift Truck E1.6-2.0XN (E30-40XN) (A269................1410 Hydraulic Pump and Motor....................................................1410 Hydraulic Tank..............................................................1410 Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276................1410 Hydraulic Pump and Motor....................................................1410 Hydraulic Tank..............................................................1410 tables..............................................................................1363 Table 1. Hydraulic Pump Motor...................................................1408 Table 2. Hydraulic Pump Motor...................................................1408 Table 3. Hydraulic Pump Motor...................................................1409 PM......................................................................................1413 toc.................................................................................1413 Periodic Maintenance............................................................1413 Safety Precautions Maintenance and Repair.......................................1414 General.........................................................................1419 Serial Number Data..........................................................1419 Discharging the Capacitors..................................................1419 How to Move Disabled Lift Truck.............................................1420 How to Tow Lift Truck...................................................1420 How to Put Lift Truck on Blocks.............................................1421 How to Raise Drive Tires................................................1421 How to Raise Steering Tires.............................................1421 How to Clean a Lift Truck...................................................1422 Safety Procedures When Working Near Mast........................................1423 WHEN WORKING NEAR THE MAST ALWAYS:..........................................1423 Maintenance Schedule............................................................1425 Maintenance Procedures Every 8 Hours or Daily...................................1429 How to Make Checks With Key or Keyless Switch OFF...........................1429 Tires and Wheels........................................................1429 Forks...................................................................1429 General.............................................................1429 Inspect.............................................................1430 Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Att........1430 Safety Labels...........................................................1431 Steering Column Adjustments.............................................1432 Tilt Adjust Feature.................................................1432 Tilt Memory Feature.................................................1432 Telescopic Feature..................................................1432 Operator Restraint System...............................................1432 Emergency Locking Retractor (ELR).......................................1433 Battery Restraint System................................................1434 Battery.................................................................1437 Hydraulic System........................................................1438 How to Make Checks With Key or Keyless Switch ON............................1440 Horn, Lights, and Backup Alarm..........................................1440 Motion Alarm............................................................1440 Steering System.........................................................1440 Service Brakes..........................................................1440 Parking Brake...........................................................1441 Hydraulic Control Levers and Pedals.....................................1441 Direction and Speed Control Pedals......................................1441 Lift System Operation...................................................1441 Oil Leaks...............................................................1441 Maintenance Procedures Every 500 Hours or Three Months..........................1442 Forks.......................................................................1442 Remove..................................................................1442 Inspect.................................................................1443 Install.................................................................1443 Adjustment..............................................................1443 Header Hose Checks..........................................................1443 Mast Lubrication............................................................1444 Parking Brake Adjustment....................................................1447 Brake Fluid Check...........................................................1448 Master Cylinder Fluid Check.............................................1448 Operator Presence System Check..............................................1450 Differential and Speed Reducer..............................................1450 Tilt Cylinder Rod End Pins..................................................1452 Lift Chains.................................................................1452 Wear Check..............................................................1452 Lift Chain Lubrication......................................................1453 Fork Pins and Guides........................................................1453 Check Upper and Lower Bearings, Integral Sideshift Carriage.................1454 Check Lower Mounting Hook, Integral Sideshift Carriage......................1454 Steering King Pins..........................................................1455 Hydraulic Tank Breather, Check..............................................1455 Other Lubrication...........................................................1457 Contactor...................................................................1457 Maintenance Procedures Every 2000 Hours or Yearly...............................1458 Hydraulic System............................................................1458 Hydraulic Filter Element, Replace.......................................1458 Hydraulic Tank Breather, Change.........................................1460 Differential and Speed Reducer Oil Change...................................1462 Brake Fluid Replacement.....................................................1464 Service Brakes..............................................................1464 Forks.......................................................................1465 Integral Sideshift Carriage, Replace Upper and Lower Bearings...............1465 Lift Chains.................................................................1465 Wheel Bearings..............................................................1465 Steer Wheels, Lubrication...............................................1465 Drive Wheels, Lubrication...............................................1465 Maintenance Procedures Every 4000 Hours or Two Years............................1466 Hydraulic Oil, Change.......................................................1466 Steering Direction Sensor Inspection........................................1468 Fixed Steering Column...................................................1468 Telescopic Steering Column..............................................1469 Telescopic Steering Column Lubrication......................................1470 Battery Maintenance.............................................................1471 How to Charge Battery.......................................................1471 How to Change Batteries.....................................................1472 General.................................................................1472 Remove the Battery......................................................1472 Install the Battery.....................................................1477 Lift and Tilt System Leak Check.................................................1478 Lift Cylinders Leak Check...................................................1478 Tilt Cylinder Leak Check....................................................1478 Lift Chain Adjustments..........................................................1478 Welding Repairs.................................................................1480 Overhead Guard Changes..........................................................1480 Wheels and Tires................................................................1481 General.....................................................................1481 Remove Wheels From Lift Truck...............................................1481 Remove and Install Tire on Wheel............................................1481 Adhesives and Sealants..........................................................1482 tables..............................................................................1413 Table 1. Maintenance Schedule...................................................1426 Table 2. Hook-Type Carriage Chain Adjustment....................................1479 Specs...................................................................................1485 toc.................................................................................1485 Capacities and Specifications...................................................1485 Safety Precautions Maintenance and Repair.......................................1486 Counterweights..................................................................1489 Hydraulic System................................................................1489 Steering System.................................................................1490 Specifications..............................................................1490 Turning Radius..............................................................1490 Wheels and Tires................................................................1491 Battery Specifications..........................................................1492 Capacities......................................................................1493 Tilt Angles.....................................................................1493 Drift Rates (Maximum) for Tilt Cylinders........................................1494 Mast Speeds.....................................................................1494 Torque Specifications...........................................................1501 Frame.......................................................................1501 Drive Axle..................................................................1501 Differential and Speed Reducer..............................................1501 Brake System................................................................1501 Steering Axle...............................................................1502 Masts.......................................................................1502 Tilt Cylinders..............................................................1502 Hydraulic Pump and Motor....................................................1502 Hydraulic Tank..............................................................1503 Hydraulic Control Valves....................................................1503 Manual Valve............................................................1503 Manual Handles and Levers...............................................1503 Manual Valve Covers.....................................................1503 E-Hydraulic Valve.......................................................1503 Electrical System...........................................................1504 Adhesives and Sealants..........................................................1504 tables..............................................................................1485 Table 1. Manual Hydraulic Control Valve.........................................1489 Table 2. E-Hydraulic Control Valve..............................................1489 Table 3. Lift/Lower Speed, Standard Performance, 36 Volts.......................1494 Table 4. Lift/Lower Speed, Standard Performance, 48 Volts.......................1496 Table 5. Lift/Lower Speed Enhanced Performance, 48 Volts........................1497 Table 6. Lift/Lower Speed, Enhanced Performance, 80 Volts.......................1499 Steer Axle..............................................................................1507 toc.................................................................................1507 Steering Axle...................................................................1507 Safety Precautions Maintenance and Repair.......................................1508 General.........................................................................1511 Steering Axle Assembly Repair...................................................1512 Remove E2.2-3.5XN (E40-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A............1512 Disassemble.................................................................1513 Clean.......................................................................1514 Inspect.....................................................................1515 Assemble....................................................................1516 Install E2.2-3.5 (E40-70) (A268)............................................1516 Install E1.6-2.0XN (E30-40XN) (A269) .......................................1517 Remove J2.2-3.5XN (J45-70XN) (A276).........................................1518 Disassemble.................................................................1519 Clean.......................................................................1521 Inspect.....................................................................1521 Assemble....................................................................1521 Install.....................................................................1522 Remove J1.6-2.0XN (J30-40XN) (A935).........................................1523 Disassemble.................................................................1523 Clean.......................................................................1525 Inspect.....................................................................1525 Assemble....................................................................1525 Install.....................................................................1526 Tie Rod Replacement.............................................................1527 Remove E2.2-E3.5XN (E45-70XN) (A268)........................................1527 Clean.......................................................................1527 Inspect.....................................................................1527 Install.....................................................................1528 Remove E1.6-2.0XN (E30-40XN) (A269).........................................1528 Clean.......................................................................1529 Inspect.....................................................................1529 Install.....................................................................1529 Remove J2.0-3.5XN (J45-70XN) (A276).........................................1529 Clean.......................................................................1529 Inspect.....................................................................1530 Install.....................................................................1530 Remove J1.6-2.0XN (J30-40XN) (A935).........................................1530 Clean.......................................................................1531 Inspect.....................................................................1531 Install.....................................................................1531 Spindle Repair..................................................................1531 Remove E2.2-3.5XN (E40-70XN) (A268).........................................1531 Disassemble.................................................................1533 Clean.......................................................................1533 Inspect.....................................................................1533 Assemble....................................................................1533 Install.....................................................................1534 Remove E1.6-2.0XN (E30-40XN) (A269).........................................1535 Disassemble.................................................................1535 Clean.......................................................................1536 Inspect.....................................................................1536 Assemble....................................................................1536 Install.....................................................................1537 Remove J2.2-3.5XN (J45-70XN) (A276).........................................1537 Disassemble.................................................................1538 Clean.......................................................................1538 Inspect.....................................................................1538 Assemble....................................................................1539 Install.....................................................................1539 Remove J1.6-2.0XN (J30-40XN) (A935).........................................1540 Disassemble.................................................................1540 Clean.......................................................................1542 Inspect.....................................................................1542 Assemble....................................................................1542 Install.....................................................................1542 Steering Cylinder Repair........................................................1543 Remove E2.2-E3.5XN (E45XN-70XN) (A268) and J2.2-3.5XN (J45-70XN)............1543 Disassemble.................................................................1544 Clean.......................................................................1545 Inspect.....................................................................1546 Assemble....................................................................1546 Install.....................................................................1546 Remove E1.6-2.0XN (E30-40XN) (A269).........................................1546 Disassemble ................................................................1547 Clean.......................................................................1548 Inspect.....................................................................1549 Assemble....................................................................1549 Install.....................................................................1549 Remove J1.6-2.0XN (J30-40XN) (A935).........................................1549 Disassemble.................................................................1550 Clean.......................................................................1551 Inspect.....................................................................1551 Assemble....................................................................1551 Install.....................................................................1552 Steer System............................................................................1555 toc.................................................................................1555 Steering System.................................................................1555 Safety Precautions Maintenance and Repair.......................................1556 General.........................................................................1559 Discharging The Capacitors..................................................1559 Steering Control Unit (SCU) Repair..............................................1560 Remove......................................................................1560 Disassemble.................................................................1562 Clean.......................................................................1564 Inspect.....................................................................1564 Assemble....................................................................1564 Install.....................................................................1565 Steering Wheel and Fixed Steering Column Assembly Repair........................1566 Remove......................................................................1566 Disassemble.................................................................1568 Clean.......................................................................1570 Inspect.....................................................................1570 Assemble....................................................................1570 Install.....................................................................1571 Fixed Steering Column Gear Replacement......................................1572 Steering Wheel and Telescopic Column Assembly Repair............................1573 Remove......................................................................1573 Disassemble.................................................................1575 Clean.......................................................................1579 Inspect.....................................................................1579 Assemble....................................................................1580 Install.....................................................................1581 Telescopic Steering Column Gear Replacement.................................1582 Torque Specifications...........................................................1587 Steering Control Unit.......................................................1587 Steering Column.............................................................1587 User Int. Sup...........................................................................1591 toc.................................................................................1591 User Interface..................................................................1591 Safety Precautions Maintenance and Repair.......................................1592 General.........................................................................1597 Description.................................................................1597 Display Panel Menu Access...................................................1597 Menu Flowchart..................................................................1598 Supervisor Menu Flowchart...................................................1598 Menu Navigation.................................................................1604 Main Menu Structure.........................................................1604 Screens and Title Screens...................................................1604 Submenus....................................................................1605 Returning to the Main Menu..................................................1606 Icons and Settings..........................................................1606 Soft Keys...................................................................1606 Entering Numbers............................................................1607 Icon Glossary...................................................................1607 Introduction................................................................1607 Soft Key Icons..............................................................1607 Overlay Icons...............................................................1609 Icons on System Off Screen and Alert Screens................................1609 Main Menu Title Screens.....................................................1612 Submenu Icons Grouped by Menu...............................................1614 Operating Screen Icons..................................................1614 Password Screen Icons...................................................1615 Activity Log Submenu Icons..............................................1615 Calibration Submenu Icons...............................................1617 Display Submenu Icons...................................................1620 Status Submenu Icons....................................................1622 Truck Setup Submenu Icons...............................................1625 Operating Screen................................................................1631 Introduction................................................................1631 Performance Mode Controls...................................................1631 Status and Warning Icons....................................................1632 Battery Discharge Indicator.................................................1633 Direction and Parking Brake Indicators......................................1633 Hazard Flashers and Lighting Controls.......................................1634 Tire Angle Indicator........................................................1634 System Time.................................................................1634 Load Weight Indicator.......................................................1634 System Off/Alert Screens........................................................1634 Introduction................................................................1634 System Off Screen...........................................................1634 Alert Screens...............................................................1635 Password Screen.................................................................1636 Introduction................................................................1636 Password Screen.............................................................1636 Service Technician Password Setup.......................................1637 Adding/Removing/Changing Passwords..........................................1638 Password Log................................................................1641 Activity Log Menu...............................................................1641 Introduction................................................................1641 Operator Checklist Log......................................................1642 Password Log................................................................1644 Impact Events Log...........................................................1645 Calibration Menu................................................................1647 Introduction................................................................1647 Load Weight Calibration.....................................................1647 Return to Set Tilt Stop Point Calibration...................................1648 E-Hydraulic and Manual Valve Threshold Calibration..........................1648 Steering Wheel Knob Center Point Calibration................................1649 Steer Axle Position Calibration.............................................1649 Manual Hydraulics Calibration...............................................1650 Display Menu....................................................................1650 Introduction................................................................1650 Set Date and Time Format Menu...............................................1651 Set Daylight Saving Time Menu...............................................1652 Procedure for Setting Up Automatic Daylight Savings Time................1653 Set Time and Date Menu......................................................1655 Procedure for Setting Time and Date.....................................1656 Set Units Menu..............................................................1656 Status Menu.....................................................................1657 Introduction................................................................1657 VSM Versions................................................................1657 Display Versions............................................................1658 Truck Serial Number.........................................................1658 Hour Meters.................................................................1658 E-Hydraulic Controller Versions.............................................1658 Pump Motor Controller Versions..............................................1658 Traction Motor Controller 1 Versions........................................1659 Traction Motor Controller 2 Versions........................................1659 Light Controller Versions...................................................1659 Impact Sensor Versions......................................................1659 Truck Setup Menu................................................................1659 Introduction................................................................1659 Add/Remove Password.........................................................1660 Restore Default Settings....................................................1660 Motion Alarm................................................................1660 Impact Monitor Settings.....................................................1661 Impact Detection........................................................1661 Setting Adjustments.....................................................1661 Initial Adjustment of Soft and Hard Impact Settings.....................1661 Readjustment of Soft and Hard Impact Settings...........................1662 Auto Power-Off Time Delay...................................................1662 Return to Set Tilt..........................................................1662 Traction Speed Limit........................................................1663 Scheduled Maintenance Reminder..............................................1663 Minimum Pump Standby Flow Rate..............................................1664 Operator Checklist..........................................................1664 Impact Monitor Shutdown.....................................................1665 Motor Braking...............................................................1666 Changing the Motor Braking Settings.....................................1666 tables..............................................................................1591 Table 1. Supervisor Menu Flowchart..............................................1603 Table 2. Soft Key Icons.........................................................1608 Table 3. Overlay Icons..........................................................1609 Table 4. Alert Screen Icons.....................................................1609 Table 5. Main Menu Title Screens................................................1612 Table 6. Operating Screen Icons.................................................1614 Table 7. Password Screen Icons..................................................1615 Table 8. Activity Log Submenus and Icons........................................1615 Table 9. Calibration Submenus and Icons.........................................1617 Table 10. Display Submenus and Icons............................................1620 Table 11. Status Submenus and Icons.............................................1622 Table 12. Truck Setup Submenu Icons.............................................1625 Table 13. BSOC in Relation to BDI...............................................1633 Table 14. Add Password..........................................................1638 Table 15. Change or Remove Password.............................................1640 Table 16. Access Operator Checklist Log Screens.................................1643 Table 17. Access Password Log Screens...........................................1645 Table 18. Access Impact Events Log Screens......................................1646 Table 19. Accessing the Set Date and Time Format Screen.........................1652 Table 20. Set Daylight Saving Time Menu.........................................1654 User Int. Tech..........................................................................1669 toc.................................................................................1669 User Interface..................................................................1669 Safety Precautions Maintenance and Repair.......................................1670 General.........................................................................1675 Description.................................................................1675 Display Panel Menu Access...................................................1675 Menu Flowchart..................................................................1676 Technician Menu Flowchart...................................................1676 Menu Navigation.................................................................1682 Main Menu Structure.........................................................1682 Screens and Title Screens...................................................1682 Submenus....................................................................1683 Returning to the Main Menu..................................................1684 Icons and Settings..........................................................1684 Soft Keys...................................................................1684 Entering Numbers............................................................1685 Icon Glossary...................................................................1685 Introduction................................................................1685 Soft Key Icons..............................................................1685 Overlay Icons...............................................................1687 System Off Screen and Alert Screens.........................................1687 Main Menu Title Screens.....................................................1690 Submenu Icons Grouped by Menu...............................................1692 Operating Screen Icons..................................................1692 Password Screen Icons...................................................1693 Activity Log Submenu Icons..............................................1693 Calibration Submenu Icons...............................................1694 Display Submenu Icons...................................................1697 Status Submenu Icons....................................................1699 Truck Setup Submenu Icons...............................................1703 Diagnostics Submenu Icons...............................................1715 Operating Screen................................................................1722 Introduction................................................................1722 Performance Mode Controls...................................................1723 Status and Warning Icons....................................................1724 Battery Discharge Indicator.................................................1724 Direction and Parking Brake Indicators......................................1725 Hazard Flashers and Lighting Controls.......................................1725 Tire Angle Indicator........................................................1725 System Time.................................................................1726 Load Weight Indicator.......................................................1726 System Off/Alert Screens........................................................1726 Introduction................................................................1726 System Off Screen...........................................................1726 Alert Screens...............................................................1727 Password Screen.................................................................1728 Introduction................................................................1728 Password Screen.............................................................1728 Service Technician Password Setup.......................................1729 Adding/Removing/Changing Passwords..........................................1730 Password Log................................................................1731 Activity Log Menu...............................................................1733 Introduction................................................................1733 Operator Checklist Log......................................................1734 Password Log................................................................1736 Impact Events Log...........................................................1737 Calibration Menu................................................................1739 Introduction................................................................1739 Load Weight Calibration.....................................................1739 Return to Set Tilt Stop Point Calibration...................................1740 E-Hydraulic and Manual Valve Threshold Calibration..........................1740 Steering Wheel Knob Center Point Calibration................................1741 Steer Axle Position Calibration.............................................1742 Manual Hydraulics Calibration...............................................1742 Display Menu....................................................................1743 Introduction................................................................1743 Set Date and Time Format Menu...............................................1743 Set Daylight Saving Time Menu...............................................1745 Procedure for Setting Up Automatic Daylight Savings Time................1745 Set Time and Date Menu......................................................1747 Procedure for Setting Time and Date.....................................1748 Set Units Menu..............................................................1748 Status Menu.....................................................................1749 Introduction................................................................1749 VSM Versions................................................................1749 Display Versions............................................................1750 Truck Serial Number.........................................................1750 Hour Meters.................................................................1750 E-Hydraulic Controller Versions.............................................1750 Pump Motor Controller Versions..............................................1750 Traction Motor Controller 1 Versions........................................1751 Traction Motor Controller 2 Versions........................................1751 Light Controller Versions...................................................1751 Impact Sensor Versions......................................................1751 Truck Setup Menu................................................................1751 Introduction................................................................1751 Add/Remove Password.........................................................1752 Motor Braking...............................................................1752 Changing the Motor Braking Settings.....................................1753 Battery Setup...............................................................1753 BDI Adjustment Setting......................................................1755 Acceleration Rates..........................................................1755 Hour Meter Initialization...................................................1756 Impact Monitor Shutdown.....................................................1756 Operator Checklist..........................................................1757 Minimum Pump Standby Flow Rate..............................................1757 Scheduled Maintenance Reminder..............................................1758 Traction Speed Limit........................................................1759 Return to Set Tilt..........................................................1759 Auto Power-Off Time Delay...................................................1760 Impact Monitor Settings.....................................................1760 Impact Detection........................................................1760 Setting Adjustments.....................................................1761 Initial Adjustment of Soft and Hard Impact Settings.....................1761 Readjustment of Soft and Hard Impact Settings...........................1761 Motion Alarm................................................................1761 Lift Hydraulic Function Maximum Speed and Ramp Times........................1762 Lower Hydraulic Function Maximum Speed and Ramp Times.......................1762 Tilt Forward Hydraulic Function Maximum Speed and Ramp Times................1762 Tilt Backward Hydraulic Function Maximum Speed and Ramp Times...............1763 Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times................1763 Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times................1763 Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times................1763 Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times................1763 Optional Hydraulic Functions................................................1763 Rear Lights Control.........................................................1764 Restore Default Settings....................................................1764 Diagnostics Menu................................................................1765 Introduction................................................................1765 Fault Code Log..............................................................1765 Fault Log Details.......................................................1766 Speedometer.................................................................1767 Direction Switch............................................................1767 Traction Motor 1 Status.....................................................1767 Traction Motor 2 Status.....................................................1768 Occupancy Sensor............................................................1768 Brake System Sensors........................................................1768 Pump Status.................................................................1768 Hydraulic Control Inputs....................................................1769 E-Hydraulic Valves..........................................................1769 Hydraulic Sensors...........................................................1770 System Voltages.............................................................1770 Steering Position Sensors...................................................1771 tables..............................................................................1669 Table 1. Technician Menu Flowchart..............................................1681 Table 2. Soft Key Icons.........................................................1686 Table 3. Overlay Icons..........................................................1687 Table 4. Alert Screen Icons.....................................................1687 Table 5. Main Menu Title Screens................................................1690 Table 6. Operating Screen Icons.................................................1692 Table 7. Password Screen Icons..................................................1693 Table 8. Activity Log Submenus and Icons........................................1693 Table 9. Calibration Submenus and Icons.........................................1695 Table 10. Display Submenus and Icons............................................1697 Table 11. Status Submenus and Icons.............................................1699 Table 12. Truck Setup Submenu Icons.............................................1703 Table 13. Diagnostic Submenu Icons..............................................1715 Table 14. BSOC in Relation to BDI...............................................1725 Table 15. Add Password..........................................................1730 Table 16. Change or Remove Password.............................................1732 Table 17. Access Operator Checklist Log Screens.................................1735 Table 18. Access Password Log Screens...........................................1737 Table 19. Access Impact Events Log Screens......................................1738 Table 20. Accessing the Set Date and Time Format Screen.........................1744 Table 21. Set Daylight Saving Time Menu.........................................1746 Table 22. Battery Setup Factory Defaults........................................1754 Binder1.....................................................................................1775 Brakes..................................................................................1775 toc.................................................................................1775 Brake System....................................................................1775 Safety Precautions Maintenance and Repair.......................................1776 General.........................................................................1779 Dry Brake System............................................................1779 Service Brakes Repair (Dry Brake)...............................................1780 Remove and Disassemble......................................................1780 Clean.......................................................................1783 Inspect.....................................................................1784 Assemble and Install........................................................1784 Adjust......................................................................1790 Parking Brake Repair............................................................1790 Remove and Disassemble......................................................1790 Inspect.....................................................................1793 Assemble and Install........................................................1793 Adjust......................................................................1795 Master Cylinder Repair..........................................................1796 Remove......................................................................1796 Disassemble.................................................................1796 Clean.......................................................................1797 Inspect.....................................................................1797 Assemble....................................................................1798 Bench Bleed Master Cylinder.................................................1798 Install and Adjust..........................................................1798 Brake Pedal Components..........................................................1799 Remove......................................................................1799 Disassemble.................................................................1801 Inspect.....................................................................1801 Assemble....................................................................1801 Install.....................................................................1801 Automatic Park Brake............................................................1802 General.....................................................................1802 Remove......................................................................1802 Manual Release Handle...................................................1802 Automatic Park Brake Assembly...........................................1804 Automatic Park Brake Module.............................................1804 Disassemble.................................................................1804 Clean and Inspect...........................................................1804 Assemble....................................................................1805 Install.....................................................................1805 Automatic Park Brake Module.............................................1805 Manual Release Handle...................................................1805 Automatic Park Brake Assembly...........................................1805 Adjustments.................................................................1805 Service Brakes Adjustment (Dry Brake)...........................................1805 Brake Adjust................................................................1805 Parking Brake Adjustment........................................................1807 Brake System Air Removal........................................................1807 Brake System Air Removal....................................................1807 Using Pressure Bleed System.................................................1807 Using Brake Pedal Pressure..................................................1807 Brake Pedal Adjustment..........................................................1808 Brake Pedal Adjustment......................................................1808 Master Cylinder Adjustment......................................................1809 Adjust Push Rod.............................................................1809 Parking Brake Not Applied Switch Test...........................................1809 Torque Specifications...........................................................1810 Cab.....................................................................................1813 toc.................................................................................1813 Operator's Cab..................................................................1813 Safety Precautions Maintenance and Repair.......................................1814 Window Replacement..............................................................1817 Front Panel.................................................................1817 Remove..................................................................1817 Clean...................................................................1817 Inspect.................................................................1818 Install.................................................................1818 Rear Panel..................................................................1818 Remove..................................................................1818 Clean...................................................................1821 Inspect.................................................................1821 Install.................................................................1821 Door Window.................................................................1822 Disassemble Window......................................................1822 Clean...................................................................1823 Inspect.................................................................1823 Assemble Window.........................................................1823 Window Wipers Replacement.......................................................1823 Front Wiper Assembly........................................................1823 Remove..................................................................1823 Clean...................................................................1827 Inspect.................................................................1827 Install.................................................................1827 Cab Component Repair............................................................1828 Roof Liner..................................................................1828 Remove..................................................................1828 Clean...................................................................1829 Inspect.................................................................1829 Install.................................................................1829 Top Panel...................................................................1829 Remove..................................................................1829 Clean...................................................................1831 Inspect.................................................................1831 Install.................................................................1831 Cab Door Assembly...............................................................1832 Door Assembly...............................................................1832 Remove..................................................................1832 Disassemble Left Door...................................................1835 Disassemble Right Door..................................................1837 Clean...................................................................1837 Inspect.................................................................1837 Assemble Right Door.....................................................1839 Assemble Left Door......................................................1839 Install.................................................................1839 Cab Heater......................................................................1840 Cab Heater..................................................................1840 Remove..................................................................1840 Clean...................................................................1840 Inspect.................................................................1840 Install.................................................................1843 Troubleshooting.........................................................1843 Weather Panel Replacement for Lift Truck Model E2.2-3.5XN (E45-7................1846 Remove......................................................................1846 Roof Panels.............................................................1846 Front Screen Panel......................................................1846 Install.....................................................................1848 Front Screen Panel......................................................1848 Roof Panels.............................................................1849 tables..............................................................................1813 Table 1. Connector C1...........................................................1845 Table 2. Connector C2...........................................................1845 Table 3. Connector C3...........................................................1845 Table 4. Connector C4...........................................................1845 Table 5. Connector C5...........................................................1845 Table 6. Connector C6...........................................................1845 Table 7. Connector C7...........................................................1845 Control Valve...........................................................................1853 toc.................................................................................1853 Main Control Valves.............................................................1853 Safety Precautions Maintenance and Repair.......................................1854 General.........................................................................1859 Lift Trucks J1.5-2.0XNT (J30-40XNT) (K160) and J1.6-2.0XN (J30-4............1859 Lift Trucks E2.2-3.5XN (E45-70XN) (A268) and J2.2-3.5XN (J45-70X............1860 Discharging the Capacitors..................................................1863 Manual Hydraulic Control Valve Repair for Lift Truck J1.5-2.0XNT................1864 Remove......................................................................1864 Beginning Steps.........................................................1864 Disassemble Covers, Links, and Levers...................................1865 Disassemble Handles and Levers..............................................1876 Disassemble Manual Control Valve............................................1878 Spool Seal Replacement......................................................1885 Clean.......................................................................1888 Inspect.....................................................................1888 Assemble Manual Control Valve...............................................1889 Assemble Handles and Levers.................................................1897 Install.....................................................................1900 Install Covers, Links, and Levers.......................................1900 Ending Steps............................................................1911 Manual Hydraulic Control Valve Repair for Lift Truck E2.2-3.5XN ................1912 Remove......................................................................1912 Remove Control Valve....................................................1914 Disassemble Handles and Levers..............................................1926 Disassemble Manual Control Valve............................................1928 Disassemble Valve.......................................................1928 Disassemble Inlet Section...............................................1932 Disassemble Lift, Tilt, and Auxiliary Sections..........................1932 Spool Seal Replacement......................................................1933 Clean.......................................................................1935 Inspect.....................................................................1935 Assemble Manual Control Valve...............................................1936 Assemble Lift, Tilt, and Auxiliary Sections.............................1936 Assemble Inlet Section..................................................1937 Assemble Valve..........................................................1938 Assemble Handles and Levers.................................................1945 Install.....................................................................1948 Install Control Valve...................................................1948 Ending Steps............................................................1959 E-Hydraulic Control Valve Repair for Lift Truck J1.5-2.0XNT (J30................1959 Remove......................................................................1959 Disassemble.................................................................1962 Clean.......................................................................1968 Inspect.....................................................................1968 Assemble....................................................................1968 Install.....................................................................1973 E-Hydraulic Controls........................................................1977 Replace E-Hydraulic Control Components..................................1977 E-Hydraulic Control Valve Repair for Lift Truck E2.2-3.5XN (E45-................1978 Remove......................................................................1978 Initial Steps...........................................................1978 Fitting Removal for Lift Truck E2.2-3.5XN (E45-70XN) (A268).............1978 Fitting Removal for Lift Truck J2.2-3.5XN (J45-70XN) (A276).............1979 Electrical Disconnect and Control Valve Dismount........................1980 Disassemble.................................................................1983 Clean.......................................................................1985 Inspect.....................................................................1986 Assemble....................................................................1986 Install.....................................................................1992 Electrical Connect and Control Valve Mount..............................1992 Fitting Installation for Lift Truck E2.2-3.5XN (E45-70XN) (A268)........1995 Fitting Installation for Lift Truck J2.2-3.5XN (J45-70XN) (A276)........1996 Ending Steps............................................................1997 E-Hydraulic Controls........................................................1997 Replace E-Hydraulic Control Components..................................1998 Checks and Adjustments for Lift Truck J1.5-2.0XNT (J30-40XNT) (K................1998 Manual Control Valve........................................................1998 Primary Relief Valve....................................................1998 Optional Work Port Relief Valve.........................................1999 E-Hydraulic Control Valve...................................................1999 Primary Relief Valve....................................................1999 Optional Secondary Port Relief Valve....................................2000 Hydraulic System Air Removal................................................2000 Checks and Adjustments for Lift Truck E2.2-3.5XN (E45-70XN) (A26................2001 Manual Control Valve........................................................2001 External Leakage........................................................2001 Primary Relief Cartridge................................................2001 Secondary Relief Valve..................................................2002 E-Hydraulic Control Valve...................................................2002 Primary Relief Valve....................................................2002 Secondary Relief Valve..................................................2003 PPRV Pilot Pressure Test................................................2003 Hydraulic System Air Removal................................................2005 Position Sensor and OPS Check and Adjustment....................................2005 Position Sensor.............................................................2005 (OPS) Operator Presence Solenoid............................................2006 Manual Control Valve Re-Calibration.........................................2006 Calibration Procedure...........................................................2006 Control Valve...............................................................2006 Torque Specifications for Lift Truck J1.5-2.0XNT (J30-40XNT) (K1................2008 Manual Hydraulic Control Valve..............................................2008 Manual Control Valve Handles and Levers.....................................2008 E-Hydraulic Control Valve...................................................2008 Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268................2009 Manual Hydraulic Control Valve..............................................2009 Manual Control Valve Handles and Levers.....................................2009 Manual Control Valve Covers.................................................2009 E-Hydraulic Control Valve...................................................2009 tables..............................................................................1853 Table 1. Handle Options.........................................................1897 Table 2. Position Sensor Connector Pin Layout...................................1912 Table 3. Position Sensor Electrical Connector Pin Layout........................1940 Table 4. Handle Options.........................................................1945 Table 5. Lower Solenoid Connector Pin Layout....................................1973 Table 6. Upper Solenoid Connector Pin Layout....................................1973 Table 7. Lower Solenoid Connector Pin Layout....................................1992 Table 8. Upper Solenoid Connector Pin Layout....................................1992 Table 9. Pressure Specifications................................................2003 Table 10. Test Specifications...................................................2003 Table 11. Service Tools.........................................................2003 Table 12. Position Sensor Wiring................................................2005 Table 13. Sensor Power Check....................................................2005 Diagrams................................................................................2013 toc.................................................................................2013 Diagrams........................................................................2013 Safety Precautions Maintenance and Repair.......................................2014 Drive Axle..............................................................................2049 toc.................................................................................2049 Drive Axle, Speed Reducer, and Differential.....................................2049 Safety Precautions Maintenance and Repair.......................................2050 General.........................................................................2053 Drive Axle Repair...............................................................2053 Remove......................................................................2053 Disassemble.................................................................2055 Clean.......................................................................2058 Inspect.....................................................................2058 Assemble....................................................................2058 Install.....................................................................2060 Differential Repair.............................................................2064 Remove......................................................................2064 Differential Assembly From Center Section...............................2064 Drive Pinion, Pinion Gear, and Bearings From Center Section.............2071 Disassemble.................................................................2079 Differential Assembly, Lift Truck Models E2.2-3.5XN (E45-70XN) (........2079 Differential Assembly, Lift Truck Models E1.6-2.0XN (E30-40XN) (........2081 Clean and Inspect...........................................................2084 Assemble....................................................................2085 Differential Assembly, Lift Truck Models E2.2-3.5XN (E45-70XN) (........2085 Differential Assembly, Lift Truck Models E1.6-2.0XN (E30-40XN) (........2089 Install.....................................................................2093 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)...............2093 Drive Pinion, Pinion Gear, and Bearings Into Center Section.............2095 Differential Assembly Into Center Section...............................2104 Ring Gear Backlash, Adjust..............................................2109 Ring Gear, Runout Check.................................................2110 Gear Set, Tooth Contact Pattern Check...................................2110 Torque Specifications...........................................................2113 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..............................2113 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..............................2113 tables..............................................................................2049 Table 1. Pinion Variation Numbers Examples......................................2094 Table 2. Ring and Pinion Tooth Contact Adjustment...............................2111 Table 3. Correct Tooth Contact..................................................2111 Table 4. Incorrect Tooth Contact................................................2112 DTC.....................................................................................2117 toc.................................................................................2117 Diagnostic Troubleshooting Manual...............................................2117 Safety Precautions TROUBLESHOOTING PROCEDURES...................................2118 How To Use This Troubleshooting Manual..........................................2120 General Instructions and Safety Information.................................2120 How to Use Diagnostic Troubleshooting Manual................................2120 General Instructions........................................................2121 Operational Diagnostic Procedures...............................................2123 Operational Checkout Procedures.............................................2125 Display Panel (DP) Check................................................2126 Operator Presence System Check..........................................2126 Display Backlight and Icon Power Check..................................2127 Light Circuit Check.....................................................2127 Horn Circuit Check......................................................2128 Backup Alarm Check (If equipped)........................................2128 Heater Check (If equipped)..............................................2128 Brake Pedal Check.......................................................2128 Park Brake Sensor Check.................................................2129 Park Brake Check........................................................2129 Brake and Axle Drag Check...............................................2130 Priority Flow Divider Valve Check.......................................2131 Mast Cushion Check - Free Lift Cylinder.................................2131 Lift Drift Check........................................................2132 Lift/Tilt Mast Adjustment Check.........................................2132 Tilt Function Drift Check...............................................2133 Tilt Racking Check......................................................2133 Tilt Function, Tilt Lock Piston.........................................2133 Mast Cushion Check - Main Lift Cylinder.................................2134 Mast Channel Check......................................................2134 Mast Mounting Check.....................................................2134 Chain and Header Hose Adjustment Check..................................2135 Chain Sheave Check......................................................2135 Carriage Adjustment Check...............................................2135 Carriage Adjustment Check (Standard and Integral Side Shift)............2135 Steering Relief Valve Low Pressure Check................................2136 Steering Relief Valve High Pressure Check...............................2136 Traction Motor..................................................................2137 Traction Motor..............................................................2139 Principles of Operation ................................................2139 Electrical System...............................................................2143 Troubleshooting Guidelines and Procedures...................................2151 Troubleshooting Guidelines..............................................2151 Troubleshooting Procedures..............................................2154 Troubleshooting Procedures, Identification..........................2154 Troubleshooting Procedures, Location................................2154 Troubleshooting Procedures, Structure...............................2154 Troubleshooting Procedures, Performance.............................2155 Troubleshooting Procedures, Final...................................2155 Diagnostic Trouble Codes................................................2156 Wiring Reference Data.......................................................2160 Harness Assembly Data.......................................................2163 Electrical System...........................................................2191 General Description.....................................................2191 Battery.............................................................2196 Power Distribution Module (PDM).....................................2196 Contactor.......................................................2196 Fuses...........................................................2196 Relays..........................................................2196 Wire Harnesses..................................................2197 Operator Interface..................................................2197 Display.........................................................2197 Controllers.........................................................2197 Vehicle System Manager (VSM)....................................2197 Motor Controllers...............................................2198 E-Hydraulics Mini Levers Module (MLM)...........................2199 System Controlled Outputs...........................................2200 Valve Coils.....................................................2200 Lights and Backup Alarm.........................................2201 Cab options.....................................................2201 PRINCIPLES OF OPERATION, COMPONENTS.....................................2202 Power Distribution..................................................2202 Contactor.......................................................2202 Positive Temperature Coefficient (PTC)..........................2202 Fuses...........................................................2202 Relays..........................................................2203 Operator Interface..................................................2204 Display.........................................................2204 Controllers.........................................................2205 Vehicle System Manager (VSM):...................................2205 Motor Controller................................................2207 E-Hydraulics Mini Levers Module (MLM)...........................2208 PRINCIPLES OF OPERATION, SYSTEM.........................................2209 Battery (Plug-In)...................................................2209 Key ON and Operation................................................2209 Sensors.............................................................2209 Switches............................................................2213 Outputs.............................................................2213 Relays..........................................................2213 Hydraulic Valve.................................................2213 Cab Devices.....................................................2215 Lights and Backup Alarm.........................................2215 12844.......................................................................2221 DTC 12844...................................................................2221 12836.......................................................................2221 DTC 12836...................................................................2221 12845.......................................................................2226 DTC 12845...................................................................2226 12837.......................................................................2226 DTC 12837...................................................................2226 12808.......................................................................2231 DTC 12808...................................................................2231 12810.......................................................................2231 DTC 12810...................................................................2231 12809.......................................................................2235 DTC 12809...................................................................2235 12811.......................................................................2235 DTC 12811...................................................................2235 12812.......................................................................2240 DTC 12812...................................................................2240 12820.......................................................................2246 DTC 12820...................................................................2246 12824.......................................................................2246 DTC 12824...................................................................2246 12821.......................................................................2250 DTC 12821...................................................................2250 12825.......................................................................2250 DTC 12825...................................................................2250 4098........................................................................2255 DTC 4098....................................................................2255 12852.......................................................................2259 DTC 12852...................................................................2259 12853.......................................................................2263 DTC 12853...................................................................2263 12872.......................................................................2268 DTC 12872...................................................................2268 12873.......................................................................2274 DTC 12873...................................................................2274 12832.......................................................................2279 DTC 12832...................................................................2279 12840.......................................................................2279 DTC 12840...................................................................2279 12831.......................................................................2283 DTC 12831...................................................................2283 12841.......................................................................2283 DTC 12841...................................................................2283 12800.......................................................................2288 DTC 12800...................................................................2288 12804.......................................................................2288 DTC 12804...................................................................2288 12801.......................................................................2292 DTC 12801...................................................................2292 12805.......................................................................2292 DTC 12805...................................................................2292 12816.......................................................................2297 DTC 12816...................................................................2297 12819.......................................................................2301 DTC 12819...................................................................2301 12545.......................................................................2306 DTC 12545...................................................................2306 12546.......................................................................2306 DTC 12546...................................................................2306 13056.......................................................................2313 DTC 13056...................................................................2313 13057.......................................................................2313 DTC 13057...................................................................2313 12856.......................................................................2321 DTC 12856...................................................................2321 12860.......................................................................2321 DTC 12860...................................................................2321 12864.......................................................................2321 DTC 12864...................................................................2321 12868.......................................................................2321 DTC 12868...................................................................2321 12857.......................................................................2325 DTC 12857...................................................................2325 12861.......................................................................2325 DTC 12861...................................................................2325 12865.......................................................................2325 DTC 12865...................................................................2325 12869.......................................................................2325 DTC 12869...................................................................2325 12332.......................................................................2330 DTC 12332...................................................................2330 8960........................................................................2335 DTC 8960....................................................................2335 8964........................................................................2335 DTC 8964....................................................................2335 8968........................................................................2335 DTC 8968....................................................................2335 8972........................................................................2335 DTC 8972....................................................................2335 8978........................................................................2335 DTC 8978....................................................................2335 8980........................................................................2335 DTC 8980....................................................................2335 8984........................................................................2335 DTC 8984....................................................................2335 8988........................................................................2335 DTC 8988....................................................................2335 13312.......................................................................2340 DTC 13312...................................................................2340 13316.......................................................................2340 DTC 13316...................................................................2340 13320.......................................................................2340 DTC 13320...................................................................2340 13324.......................................................................2340 DTC 13324...................................................................2340 13328.......................................................................2340 DTC 13328...................................................................2340 13332.......................................................................2340 DTC 13332...................................................................2340 13336.......................................................................2340 DTC 13336...................................................................2340 13340.......................................................................2340 DTC 13340...................................................................2340 33025.......................................................................2345 DTC 33025...................................................................2345 33026.......................................................................2345 DTC 33026...................................................................2345 33027.......................................................................2345 DTC 33027...................................................................2345 33029.......................................................................2345 DTC 33029...................................................................2345 33034.......................................................................2345 DTC 33034...................................................................2345 33035.......................................................................2345 DTC 33035...................................................................2345 33036.......................................................................2345 DTC 33036...................................................................2345 33037.......................................................................2345 DTC 33037...................................................................2345 33038.......................................................................2345 DTC 33038...................................................................2345 33057.......................................................................2345 DTC 33057...................................................................2345 33025.......................................................................2359 DTC 33025...................................................................2359 33026.......................................................................2359 DTC 33026...................................................................2359 33027.......................................................................2359 DTC 33027...................................................................2359 33029.......................................................................2359 DTC 33029...................................................................2359 33034.......................................................................2359 DTC 33034...................................................................2359 33035.......................................................................2359 DTC 33035...................................................................2359 33036.......................................................................2359 DTC 33036...................................................................2359 33037.......................................................................2359 DTC 33037...................................................................2359 33038.......................................................................2359 DTC 33038...................................................................2359 33057.......................................................................2359 DTC 33057...................................................................2359 33025.......................................................................2374 DTC 33025...................................................................2374 33026.......................................................................2374 DTC 33026...................................................................2374 33027.......................................................................2374 DTC 33027...................................................................2374 33029.......................................................................2374 DTC 33029...................................................................2374 33034.......................................................................2374 DTC 33034...................................................................2374 33035.......................................................................2374 DTC 33035...................................................................2374 33036.......................................................................2374 DTC 33036...................................................................2374 33037.......................................................................2374 DTC 33037...................................................................2374 33038.......................................................................2374 DTC 33038...................................................................2374 33057.......................................................................2374 DTC 33057...................................................................2374 21830.......................................................................2387 DTC 21830...................................................................2387 21834.......................................................................2387 DTC 21834...................................................................2387 21835.......................................................................2387 DTC 21835...................................................................2387 21836.......................................................................2387 DTC 21836...................................................................2387 21837.......................................................................2387 DTC 21837...................................................................2387 25344.......................................................................2387 DTC 25344...................................................................2387 4112........................................................................2393 DTC 4112....................................................................2393 4113........................................................................2393 DTC 4113....................................................................2393 4114........................................................................2393 DTC 4114....................................................................2393 4115........................................................................2393 DTC 4115....................................................................2393 4116........................................................................2393 DTC 4116....................................................................2393 13060.......................................................................2396 DTC 13060...................................................................2396 13061.......................................................................2396 DTC 13061...................................................................2396 22032.......................................................................2405 DTC 22032...................................................................2405 22033.......................................................................2405 DTC 22033...................................................................2405 33056.......................................................................2405 DTC 33056...................................................................2405 33057.......................................................................2405 DTC 33057...................................................................2405 8704........................................................................2405 DTC 8704....................................................................2405 12934.......................................................................2405 DTC 12934...................................................................2405 12935.......................................................................2405 DTC 12935...................................................................2405 8705........................................................................2405 DTC 8705....................................................................2405 12936.......................................................................2405 DTC 12936...................................................................2405 12937.......................................................................2405 DTC 12937...................................................................2405 22528.......................................................................2405 DTC 22528...................................................................2405 22529.......................................................................2405 DTC 22529...................................................................2405 22530.......................................................................2405 DTC 22530...................................................................2405 22531.......................................................................2405 DTC 22531...................................................................2405 22532.......................................................................2405 DTC 22532...................................................................2405 22533.......................................................................2405 DTC 22533...................................................................2405 22534.......................................................................2405 DTC 22534...................................................................2405 22535.......................................................................2405 DTC 22535...................................................................2405 22536.......................................................................2405 DTC 22536...................................................................2405 22537.......................................................................2405 DTC 22537...................................................................2405 22538.......................................................................2405 DTC 22538...................................................................2405 22539.......................................................................2405 DTC 22539...................................................................2405 22540.......................................................................2405 DTC 22540...................................................................2405 22541.......................................................................2405 DTC 22541...................................................................2405 9041........................................................................2411 DTC 9041....................................................................2411 12940.......................................................................2411 DTC 12940...................................................................2411 12941.......................................................................2411 DTC 12941...................................................................2411 21760.......................................................................2423 DTC 21760...................................................................2423 21761.......................................................................2423 DTC 21761...................................................................2423 21762.......................................................................2423 DTC 21762...................................................................2423 21764.......................................................................2423 DTC 21764...................................................................2423 21766.......................................................................2423 DTC 21766...................................................................2423 21792.......................................................................2423 DTC 21792...................................................................2423 12928.......................................................................2428 DTC 12928...................................................................2428 12929.......................................................................2428 DTC 12929...................................................................2428 9040........................................................................2428 DTC 9040....................................................................2428 12938.......................................................................2428 DTC 12938...................................................................2428 12939.......................................................................2428 DTC 12939...................................................................2428 9000........................................................................2434 DTC 9000....................................................................2434 9004........................................................................2434 DTC 9004....................................................................2434 9008........................................................................2434 DTC 9008....................................................................2434 9012........................................................................2434 DTC 9012....................................................................2434 9016........................................................................2434 DTC 9016....................................................................2434 9020........................................................................2434 DTC 9020....................................................................2434 9026........................................................................2434 DTC 9026....................................................................2434 9028........................................................................2434 DTC 9028....................................................................2434 9032........................................................................2434 DTC 9032....................................................................2434 9036........................................................................2434 DTC 9036....................................................................2434 13352.......................................................................2439 DTC 13352...................................................................2439 13356.......................................................................2439 DTC 13356...................................................................2439 13360.......................................................................2439 DTC 13360...................................................................2439 13364.......................................................................2439 DTC 13364...................................................................2439 13368.......................................................................2439 DTC 13368...................................................................2439 13372.......................................................................2439 DTC 13372...................................................................2439 13376.......................................................................2439 DTC 13376...................................................................2439 13380.......................................................................2439 DTC 13380...................................................................2439 13384.......................................................................2439 DTC 13384...................................................................2439 13388.......................................................................2439 DTC 13388...................................................................2439 21569.......................................................................2445 DTC 21569...................................................................2445 21570.......................................................................2445 DTC 21570...................................................................2445 12592.......................................................................2456 DTC 12592...................................................................2456 29456.......................................................................2463 DTC 29456...................................................................2463 25104.......................................................................2474 DTC 25104...................................................................2474 29456.......................................................................2474 DTC 29456...................................................................2474 8786........................................................................2486 DTC 8786....................................................................2486 12834.......................................................................2486 DTC 12834...................................................................2486 12835.......................................................................2486 DTC 12835...................................................................2486 65513.......................................................................2495 DTC 65513...................................................................2495 12576.......................................................................2503 DTC 12576...................................................................2503 65280.......................................................................2513 DTC 65280...................................................................2513 8976........................................................................2520 DTC 8976....................................................................2520 9024........................................................................2520 DTC 9024....................................................................2520 65527.......................................................................2531 DTC 65527...................................................................2531 33024.......................................................................2538 DTC 33024...................................................................2538 12802.......................................................................2546 DTC 12802...................................................................2546 12806.......................................................................2553 DTC 12806...................................................................2553 12807.......................................................................2557 DTC 12807...................................................................2557 16912.......................................................................2565 DTC 16912...................................................................2565 17168.......................................................................2565 DTC 17168...................................................................2565 25105.......................................................................2565 DTC 25105...................................................................2565 21008.......................................................................2578 DTC 21008...................................................................2578 4096........................................................................2584 DTC 4096....................................................................2584 20753.......................................................................2589 DTC 20753...................................................................2589 20755.......................................................................2589 DTC 20755...................................................................2589 12576.......................................................................2595 DTC 12576...................................................................2595 12817.......................................................................2595 DTC 12817...................................................................2595 12818.......................................................................2595 DTC 12818...................................................................2595 12833.......................................................................2595 DTC 12833...................................................................2595 21520.......................................................................2613 DTC 21520...................................................................2613 None........................................................................2625 DTC None....................................................................2625 None........................................................................2634 DTC None....................................................................2634 None........................................................................2647 DTC None....................................................................2647 Horn Failure................................................................2658 Icon Glossary...............................................................2663 Introduction to Icons...................................................2663 Drive Axle/Unit.................................................................2671 Drive Axle J1.5-2.0XNT (J30-40XNT) (K160) J1.6-2.0XN (A935).................2673 Description.............................................................2673 Principles of Operation.................................................2673 Drive Units.........................................................2673 Brakes..............................................................2673 Drive Axle E2.2-3.5XN (E40-70XN) (A268) E1.6-2.0XN E30-40XN (A26............2674 Description.............................................................2674 Dry Brake System........................................................2676 General.............................................................2676 Master Cylinder.....................................................2676 Parking Brake.......................................................2676 Automatic Park Brake................................................2676 MONOTROL® Pedal.........................................................2676 Description.........................................................2676 Principles of Operation.............................................2677 One Drive Wheel Will Not Move...............................................2679 Noise During Operation That Is Not Normal...................................2680 Oil Leaks...................................................................2682 Park Brake Does Not Operate Properly........................................2683 Hydraulic Systems...............................................................2685 Manual Hydraulic Main Control Valve.........................................2689 Description.............................................................2689 Manual Hydraulic Control System.........................................2689 General Description (Open Center Valve).................................2691 CONSTRUCTION........................................................2691 VALVE TYPE..........................................................2691 Features and Operation..................................................2692 INLET ASSEMBLY......................................................2692 Construction and Purpose........................................2692 Porting.........................................................2692 Priority Steer..................................................2692 Relief Cartridge................................................2693 LIFT SECTION........................................................2694 Construction....................................................2694 Purpose.........................................................2694 Load Check......................................................2695 Operator Presence Solenoid......................................2695 Position Sensor Assembly........................................2696 Mast Lowering Cartridge.........................................2697 TILT SECTION........................................................2698 Construction....................................................2698 Purpose.........................................................2698 AUXILIARY AND DUAL AUXILIARY SECTION................................2699 Construction....................................................2699 Purpose.........................................................2699 OUTLET COVER SECTION................................................2700 Construction and Purpose........................................2700 General Description (Closed Center Valve)...............................2701 CONSTRUCTION........................................................2701 VALVE TYPE..........................................................2701 Features and Operation..................................................2702 INLET ASSEMBLY......................................................2702 Construction and Purpose........................................2702 Porting.........................................................2702 Priority Steer..................................................2702 Unloading Spool and Relief Cartridge............................2703 LIFT SECTION........................................................2704 Purpose.........................................................2704 Operation - Main Spool..........................................2704 Load Check......................................................2705 Operator Presence Solenoid......................................2706 Position Sensor.................................................2706 Mast Lowering Cartridge.........................................2707 TILT SECTION........................................................2707 Construction and Purpose........................................2707 Operation.......................................................2707 Main Spool with Tilt-Lock.......................................2708 AUXILIARY AND DUAL AUXILIARY SECTIONS...............................2709 Construction and Purpose........................................2709 Operation.......................................................2710 E-Hydraulic Main Control Valve..............................................2710 Electro-Hydraulic Control System........................................2710 General Valve Description...............................................2712 Construction........................................................2712 Valve Type..........................................................2712 Features and Operation..................................................2713 Inlet Section.......................................................2713 Construction and Purpose........................................2713 Porting.........................................................2713 Priority Steer..................................................2713 Unloading Spool and Relief Cartridge............................2714 Pilot Cartridge.................................................2715 Lift Section........................................................2715 Construction and Purpose........................................2715 Operation - Main Spool..........................................2715 Load Check......................................................2717 Mast Lowering Cartridge.........................................2717 Electro-Hydraulic (EH) Solenoid.................................2718 Tilt Section........................................................2718 Construction and Purpose........................................2718 Operation.......................................................2718 Main Spool......................................................2719 Spacer Sections.....................................................2719 Construction and Purpose........................................2719 Auxiliary and Dual Auxiliary Sections...............................2720 Construction and Purpose........................................2720 Operation.......................................................2720 Steering System.............................................................2721 Description.............................................................2721 Accumulator, Piston.................................................2722 Priority Steer (E-Hydraulic Control Valve)..........................2722 Priority Steer (Manual Hydraulics Open Center Control Valve)........2723 Priority Steer (Manual Hydraulics Closed Center Control Valve)......2724 Steering Control Unit (SCU) Operation...................................2725 Abnormal Hydraulic Noise and/or Vibration...................................2727 Abnormal Smell/Discoloration/Foaming of Oil.................................2731 Cycle Times Too Fast - Fast Actuation (E-Valve).............................2732 Jump/Delay In Lift or Lower Activation After Moving MLM (E-Valve............2734 Jump/Delay In Auxiliary Function Actuation After Moving MLM (E-V............2736 Jump/Delay In Tilt Forward or Back Actuation (E-Valve)......................2738 Forks Drop Slightly Before Lifting (E-Valve)................................2739 Forks Lower Without Command (E-Valve).......................................2740 Forks Raise or Actuate Without Command (E-Valve)............................2741 Intermittent Activation (E-Valve) While Commanding Function.................2742 Forks Tilt Forward Without Command (E-Valve)................................2743 Lift/Lower Function Maximum Speed Too Slow (E-Valve)........................2746 Lift Function Will Not Move With MLM Movement (E-Valve).....................2749 Lift/Lower Continues To Move For Awhile After MLM Is Released (E............2752 Lift/Lower/Auxiliary Function Suddenly Jumps In Middle of Stroke............2753 Lower Function Will Not Move With MLM Movement (E-Valve)....................2754 Poor Metering on Lift or Lower Functions (E-Valve)..........................2755 Auxiliary Function Continues to Move for Awhile After MLM Is Rel............2758 Auxiliary Function Maximum Speed Too Slow (E-Valve).........................2759 Auxiliary Function or Tilt Back Moves Without Command (E-Valve).............2762 Auxiliary Function, Tilt Back and/or Tilt Forward Will Not Move ............2763 Tilt Forward or Tilt Back Function Continues to Move for Awhile ............2767 Tilt Forward or Tilt Back Will Not Move With MLM Movement (E-Val............2768 Too Much MLM Movement (Deadband) to Start Function Moving (E-Val............2770 Wrong Actuation Operates or Actuation is Backward (E-Valve).................2771 Actuation Exhibits Slight Movement in Opposite Direction Before ............2772 Auxiliary Function is Slow or Does Not Function (Manual Valve)..............2773 Cycle Times Too Fast - Fast Actuation (Manual Valve)........................2776 Function Continues to Activate After Returning to Neutral...................2777 Lift Function Is Slow or Does Not Function (Manual Valve)...................2778 Tilt Back Function Will Not Operate (Manual Valve)..........................2781 Tilt Forward or Tilt Back Will Not Function When Activated (Manu............2782 No Steering (All Other Hydraulic Functions OK)..............................2783 Steering Is Slow or Difficult...............................................2785 Steering Operation Is Not Smooth............................................2787 Steering Wheel End Lock Position Cannot Be Felt by Operator.................2789 Steering Wheel Turns By Itself or Does Not Return To Neutral................2790 Steering Wheel Turns the Tires in the Wrong Direction.......................2792 Actuations Do Not Act Simultaneously........................................2793 Oil Leaking/Component Life Too Short........................................2794 Abnormal Steer Axle Noise...................................................2797 Abnormal Steering Wheel Vibration...........................................2799 Back Lash/Kick Back in Steering Wheel.......................................2800 Hydraulic Warm-up Procedure.................................................2803 Primary Relief Valve Test and Adjustment....................................2804 Secondary Relief Valve Test and Adjustment..................................2806 Hydraulic Pump Flow Test....................................................2811 Main Control Valve LS Leakage Test (E-Valve)................................2813 Main Control Valve Unloader Margin Test.....................................2814 E-Hydraulic Valve Leakage Test..............................................2816 Steering Relief Pressure Test and Adjustment................................2820 Steering Control Unit LS Pressure Test......................................2823 Lift Cylinder Leakage Test..................................................2825 Tilt Cylinder Leakage Test..................................................2827 Steering Cylinder Leakage Test..............................................2830 Operators Station...............................................................2833 Operator Station General Description and Principles of Operation............2835 General Description and Location........................................2835 Display Panel...............................................................2837 General Description.....................................................2837 Common Display Panel Features.......................................2837 Premium Display Panel...............................................2837 Display Panel.......................................................2838 LCD Screen and Warning and Indicator Lights.........................2840 Programming - Menus.........................................................2841 Menu....................................................................2841 Operator Cycle Main Menu............................................2841 Supervisor/Service Cycle Main Menu..................................2841 Activity Log....................................................2841 Calibration.....................................................2841 Diagnostic......................................................2841 Truck Set-Up....................................................2842 Truck Status....................................................2842 Display Adjustments.............................................2842 Display Menu Flowchart......................................................2842 Display Menu Flowchart..................................................2842 Manual Hydraulic Control Levers.............................................2864 General Description.....................................................2864 System Components.......................................................2864 Lift/Lower..........................................................2864 Tilt................................................................2864 Auxiliary 1.........................................................2864 Auxiliary 2.........................................................2865 Emergency Disconnect Switch.........................................2865 E-Hydraulic System Interface................................................2866 General Description to E-Hydraulic System Interface.....................2866 Lift/Lower..........................................................2866 Tilt................................................................2866 Return-To-Set-Tilt (RTST).......................................2867 Auxiliary 1.........................................................2867 Auxiliary 2.........................................................2867 Emergency Disconnect Switch.........................................2868 Lighting Control............................................................2868 General Description.....................................................2868 Front Work Lights...................................................2868 Front Marker Lights.................................................2868 Front/Rear Turn Signal Lights.......................................2868 Rear Tail Lights....................................................2868 Rear Work Light.....................................................2869 Rear Backup Lights..................................................2869 Rear Stop Lights....................................................2869 Strobe Light........................................................2869 Dome Light..........................................................2869 Cab Panels..................................................................2870 General Description.....................................................2870 Covers and Floor Plates.............................................2870 Hood and Seat.......................................................2870 Hood............................................................2870 Seat............................................................2870 Cab Heating System..................................................2870 Control Panel...................................................2871 Heater Core.....................................................2871 Heater Fan......................................................2871 Wiper/Washer System.................................................2871 Front End (Mast) and Chassis....................................................2873 Front End, Mast.............................................................2875 Description.............................................................2875 Carriages...................................................................2876 Description.............................................................2876 Principles of Operation.................................................2876 Integral Sideshift Carriage.........................................2876 Mast Mounts.................................................................2878 Description.............................................................2878 Principles of Operation.................................................2878 Two-Stage Full Free-Lift (FFL) Mast.........................................2878 Description.............................................................2878 Principles of Operation.................................................2879 Two-Stage Limited Free-Lift (LFL) Mast......................................2880 Description.............................................................2880 Principles of Operation.................................................2881 Three-Stage Full Free-Lift (FFL) Mast.......................................2882 Description.............................................................2882 Principles of Operation.................................................2883 Four-Stage Full Free-Lift (FFL) Mast........................................2884 Description.............................................................2884 Principles of Operation.................................................2886 Cylinder Cushion During Lifting Sequence....................................2888 Description.............................................................2888 Principles of Operation.................................................2888 Cylinder Cushion During Lowering Sequence...................................2889 Description.............................................................2889 Principles of Operation.................................................2889 Tilt and Sideshift Cylinders................................................2890 Description.............................................................2890 Tilt Cylinder.......................................................2890 Sideshift Cylinder..................................................2890 Lowering Control Valves.....................................................2890 Description.............................................................2890 Principles of Operation.................................................2890 Chassis.....................................................................2892 Description.............................................................2892 Overhead Guard .....................................................2892 Counterweight.......................................................2892 Abnormal Channel Wear.......................................................2893 Abnormal Hose Wear..........................................................2895 Abnormal Mast Noise.........................................................2897 Body Panels Making Noise....................................................2901 External Leakage From Free-Lift or Main Lift Cylinders......................2902 FFL Mast Banging During Phasing.............................................2903 High Tire Wear - Drive Axle.................................................2905 High Tire Wear - Steer Axle.................................................2906 Hoses Not Tracking Correctly................................................2908 Integral Sideshift Moving Too Fast..........................................2909 Integral Sideshift Not Moving or Slow.......................................2910 Mast is Loose...............................................................2913 Mast Lift Chains Are Loose..................................................2915 Mast or Carriage Binding....................................................2916 Mast/Carriage Bounces or is Spongy..........................................2919 Misphasing of Full Free-Lift Mast...........................................2920 Overhead Guard Loose or Damaged.............................................2922 Racking During Lift.........................................................2923 Racking During Tilt.........................................................2925 Truck Feels Unstable........................................................2926 Truck Wanders, Does Not Track Straight or Steer Well........................2927 Wheel Studs Breaking........................................................2928 Supplementary Data..............................................................2929 Abbreviations and Acronyms..................................................2931 Fault Mode Indicator (FMI) Reference List...................................2937 tables..............................................................................2117 Table 9030-03-1. Circuit Group Identification...................................2160 Table 9030-03-2. Hyster Wiring Color Codes......................................2161 Table 9030-10-1. Silicon Temperature Sensors....................................2211 Table 9030-20-1. Main Schematic.................................................2347 Table 9030-20-2. Device Connectors..............................................2348 Table 9030-20-3. Main Schematic.................................................2361 Table 9030-20-4. Device Connectors..............................................2362 Table 9030-20-5. Main Schematic.................................................2376 Table 9030-20-6. Device Connectors..............................................2377 Table 9030-20-7. Main Schematic.................................................2389 Table 9030-20-8. Device Connectors..............................................2399 Table 9030-20-9. Display Internal Failure Fault DTCs............................2406 Table 9030-20-10. CBB Temperature Control Chart Table...........................2566 Table 9030-20-11. DBB Temperature Control Chart Table...........................2567 Table 9050-43-1. Test Specifications............................................2803 Table 9050-43-2. Service Tools..................................................2803 Table 9050-43-3. Service Tools..................................................2804 Table 9050-43-4. Test Specifications............................................2804 Table 9050-43-5. Test Specifications for Lift Trucks J1.5-2.0XNT................2806 Table 9050-43-6. Test Specifications for Lift Trucks E2.2-3.5XN ................2807 Table 9050-43-7. Service Tools..................................................2807 Table 9050-43-8. Test Specifications............................................2811 Table 9050-43-9. Service Tools..................................................2811 Table 9050-43-10. Test Specifications...........................................2813 Table 9050-43-11. Test Specifications...........................................2814 Table 9050-43-12. Service Tools.................................................2814 Table 9050-43-13. Test Specifications...........................................2817 Table 9050-43-14. Test Specifications...........................................2820 Table 9050-43-15. Service Tools.................................................2820 Table 9050-43-16. Test Specifications...........................................2823 Table 9050-43-17. Service Tools.................................................2823 Table 9050-43-18. Test Specifications...........................................2825 Table 9050-43-19. Service Tools.................................................2825 Table 9050-43-20. Test Specifications...........................................2827 Table 9050-43-21. Service Tools.................................................2827 Table 9050-43-22. Test Specifications...........................................2830 Table 9050-43-23. Service Tools.................................................2830 Table 9060-10-1. Display Panel..................................................2838 Table 9060-10-2. Activity Logs..................................................2845 Table 9060-10-3. Calibration....................................................2847 Table 9060-10-4. Diagnostics....................................................2849 Table 9060-10-5. Truck-Setup....................................................2853 Table 9060-10-6. Truck Status...................................................2859 Table 9060-10-7. Display Adjustments............................................2862 Table 9080-50-1. Abbreviations and Acronyms.....................................2931 Table 9080-70-1. FMI............................................................2937 Electrical System.......................................................................2941 toc.................................................................................2941 Electrical System...............................................................2941 Safety Precautions Maintenance and Repair.......................................2942 General.........................................................................2949 Discharging the Capacitors..................................................2950 Display Panel and Key or Keyless Switch Replacement.............................2951 Display Panel, Replace......................................................2951 Remove..................................................................2951 Install.................................................................2952 Electronic and Manual Hydraulic Controls........................................2954 General.....................................................................2954 Manual Hydraulic Controls...................................................2954 Upper Front Cover.......................................................2954 Direction Control Switch................................................2956 Remove..............................................................2956 Install.............................................................2956 Clamp Button............................................................2960 Remove..............................................................2960 Install.............................................................2960 Emergency Disconnect Switch.............................................2960 Remove..............................................................2960 Install.............................................................2961 E-Hydraulic Controls - Test.................................................2962 Mini-Levers.............................................................2962 Full Stroke Test........................................................2962 Function Returns to Neutral Test........................................2962 Push Button Switch......................................................2962 E-Hydraulic Controls........................................................2962 Mini-levers, Remove and Install.........................................2963 Armrest Assembly........................................................2964 Remove..............................................................2964 Install.............................................................2965 Horn Button.............................................................2966 Remove..............................................................2966 Install.............................................................2966 Direction Control Switch................................................2967 Remove..............................................................2967 Install.............................................................2967 Emergency Disconnect Switch.............................................2968 Remove..............................................................2968 Install.............................................................2968 Momentary Switches and Function Selection Button........................2969 Remove..............................................................2969 Install.............................................................2970 Sensors and Switches............................................................2971 General.....................................................................2971 Steering Axle Sensor........................................................2971 Remove..................................................................2971 Install.................................................................2973 Hydraulic Motor Speed Sensor................................................2974 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................2974 Remove..............................................................2974 Install.............................................................2974 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................2977 Remove..............................................................2977 Install.............................................................2977 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................2979 Remove..............................................................2979 Install.............................................................2979 Hydraulic Motor Temperature Sensor..........................................2979 Hydraulic Tank Level Sensor.................................................2980 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................2980 Remove..............................................................2980 Install.............................................................2980 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........2981 Remove..............................................................2981 Install.............................................................2981 Hydraulic Filter Sensor.....................................................2982 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................2982 Remove..............................................................2982 Install.............................................................2982 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........2982 Remove..............................................................2982 Install.............................................................2983 Hydraulic Oil Temperature Sensor............................................2984 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................2984 Remove..............................................................2984 Install.............................................................2984 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................2984 Remove..............................................................2984 Install.............................................................2984 Traction Speed Sensor.......................................................2985 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................2985 Remove..............................................................2985 Install.............................................................2986 E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269)...........2986 Remove..............................................................2986 Install.............................................................2986 Traction Motor Temperature Sensor...........................................2988 Tilt Position Sensor E2.2-3.5XN (E45-70XN) (A268) and J2.2-3.5XN............2988 Remove..................................................................2988 Install.................................................................2989 Tilt Position Sensor E1.6-2.0XN (E30-40XN) (A269)...........................2990 Remove..................................................................2990 Install.................................................................2990 Low Level Brake Fluid Switch................................................2990 Remove..................................................................2990 Install.................................................................2991 Service Brake Pressure Sensor...............................................2993 Remove..................................................................2993 Install.................................................................2993 Accelerator Pedal Position Sensor...........................................2993 Remove..................................................................2993 Install.................................................................2993 Seat Sensor (Operator Presence System)......................................2995 Non-Suspension Seat.....................................................2995 Remove..............................................................2995 Install.............................................................2996 Full Suspension and Swivel Seats........................................2996 Remove..............................................................2996 Install.............................................................2996 Steering Direction Sensor...................................................2997 Remove..................................................................2997 Install.................................................................2997 Load Weight Sensor..........................................................2998 Remove..................................................................2998 Install.................................................................2999 Battery Gate Switch.........................................................2999 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........3000 Remove..............................................................3000 Install.............................................................3000 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3002 Remove..............................................................3002 Install.............................................................3002 Horn Switch.................................................................3003 Fixed Steering Column...................................................3003 Remove..............................................................3003 Install.............................................................3003 Telescopic Steering Column..............................................3004 Remove..............................................................3004 Install.............................................................3005 Impact Sensor...............................................................3005 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3005 Remove..............................................................3005 Install.............................................................3006 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........3007 Remove..............................................................3007 Install.............................................................3008 Rear and Hood Horn Button Switches..........................................3008 Rear Horn Button Switch.................................................3008 Remove..............................................................3008 Install.............................................................3009 Hood Horn Button Switch.................................................3009 Remove..............................................................3009 Install.............................................................3009 Motor Controllers Replacement...................................................3011 General.....................................................................3011 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E............3015 Traction Motor and Hydraulic Pump and Motor Controllers.................3015 Remove..............................................................3015 Install.............................................................3015 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..............................3018 Hydraulic Pump and Motor Controller.....................................3018 Remove..............................................................3018 Install.............................................................3018 Traction Motor Controllers..............................................3020 Remove..............................................................3020 Install.............................................................3020 Line Contactor..............................................................3023 Remove..................................................................3023 Install.................................................................3023 Fans........................................................................3025 Remove..................................................................3025 Install.................................................................3026 Vehicle System Manager..........................................................3027 General.....................................................................3027 Remove......................................................................3027 Install.....................................................................3027 Programming a New VSM and/or Display Panel..................................3029 General.................................................................3029 PC Service Tool Software....................................................3029 Fuses and Relays................................................................3030 Fuses.......................................................................3030 Relays......................................................................3033 Backup Alarm....................................................................3036 Battery Connection..............................................................3038 Inspect.....................................................................3038 Replacing Cables............................................................3038 Cab Heater......................................................................3040 Lights..........................................................................3040 General.....................................................................3040 Work Lights (Front and Rear)................................................3043 Halogen Bulb Lights.....................................................3043 Remove..............................................................3043 Install.............................................................3043 LED Lights..............................................................3044 Remove..............................................................3044 Install.............................................................3044 Strobe Light................................................................3044 Remove..................................................................3044 Install.................................................................3044 LED Tail, Backup, and Brake Lights..........................................3045 Remove..................................................................3045 Install.................................................................3045 Front Marker/Turn Signal Lights.............................................3046 Remove..................................................................3046 Install.................................................................3046 Dome Light..................................................................3046 Remove..................................................................3046 Install.................................................................3046 Converter...................................................................3047 Remove..................................................................3047 Install.................................................................3047 Frame...................................................................................3053 toc.................................................................................3053 Frame...........................................................................3053 Safety Precautions Maintenance and Repair.......................................3054 General.........................................................................3057 General.....................................................................3057 Frame.......................................................................3057 Discharging the Capacitors..................................................3061 Overhead Guard Replacement for Lift Trucks E2.2-3.5XN (E45-70XN)................3062 Remove......................................................................3062 Install.....................................................................3064 Overhead Guard Replacement for Lift Truck Models J2.2-3.5XN (J45................3065 Remove......................................................................3065 Install.....................................................................3067 Battery Restraint and Seat Assembly Repair......................................3068 Operator Restraint System and Seat Assembly.................................3073 Operator Restraint System...............................................3073 Emergency Locking Retractor (ELR)...................................3075 Armrest Assembly Repair.................................................3076 Remove..............................................................3076 Disassemble.........................................................3078 Clean...............................................................3079 Inspect.............................................................3079 Assemble............................................................3079 Install.............................................................3080 Hood and Seat Latches...................................................3080 Hood and Seat Assembly Replacement for Lift Truck Models E2.2-3.................3081 General.....................................................................3081 Remove......................................................................3085 Install.....................................................................3090 Ground Test.................................................................3091 Hood and Seat Assembly Replacement for Lift Truck Models J2.2-3.................3091 General.....................................................................3091 Opening and Closing the Hood............................................3094 Remove......................................................................3095 Install.....................................................................3097 Ground Test.................................................................3098 Master Cylinder Repair and Adjustment for Lift Truck E2.2-3.5XN ................3099 Master Cylinder Repair and Adjustment for Lift Truck J2.2-3.5XN ................3099 Remove......................................................................3099 Disassemble.................................................................3099 Clean.......................................................................3102 Inspect.....................................................................3102 Assemble....................................................................3102 Bench Bleed Master Cylinder.................................................3102 Install and Adjust..........................................................3102 Brake Pedal Components for Lift Trucks E2.2-3.5XN (E45-70XN) (A2................3103 Brake Pedal Components for Lift Truck J2.2-3.5XN (J45-70XN) (A27................3103 Remove......................................................................3103 Disassemble.................................................................3105 Inspect.....................................................................3105 Assemble....................................................................3105 Install.....................................................................3106 Pedal Adjust................................................................3106 Brake System Air Removal for Lift Truck J2.2-3.5XN (J45-70XN) (A................3107 Brake System Air Removal....................................................3107 Using Pressure Bleed System.................................................3107 Using Brake Pedal Pressure..................................................3107 Brake System Air Removal for Lift Trucks E2.2-3.5XN (E45-70XN) (................3107 Counterweight Replacement for Lift Trucks E2.2-3.5XN (E45-70XN) ................3108 Remove......................................................................3109 Install.....................................................................3110 Counterweight Replacement for Lift Trucks J2.2-3.5XN (J45-70XN) ................3110 Remove......................................................................3112 Install.....................................................................3112 Traction Motor Replacement for Lift Trucks E2.2-3.5XN (E45-70XN)................3114 Remove......................................................................3114 Install.....................................................................3119 Traction Motor Repair or Replacement for Lift Truck J2.2-3.5XN (................3120 Hydraulic Tank Inspection.......................................................3120 Inspect.....................................................................3120 Clean.......................................................................3121 Painting Instructions...........................................................3123 Safety Label Replacement........................................................3125 Battery Specifications..........................................................3132 Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268................3134 Overhead Guard..............................................................3134 Counterweight...............................................................3134 Traction Motor..............................................................3134 Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276................3134 Overhead Guard..............................................................3134 Counterweight...............................................................3134 tables..............................................................................3053 Table 1. Counterweights for Lift Truck E2.2-3.5XN (E45-70XN) (A2................3109 Table 2. Counterweights for Lift Truck E1.6-2.0XN (E30-40XN) (A2................3109 Table 3. Counterweights for Lift Truck J2.2-3.5XN (J45-70XN) (A2................3112 Table 4. E2.2-3.5XN (E45-70XN) (A268) Model Trucks..............................3132 Table 5. J2.2-3.5XN (J45-70XN) (A276) Model Trucks..............................3133 Table 6. E1.6-2.0XN (E30-40XN) (A269) Model Trucks..............................3133 Hydraulics..............................................................................3137 toc.................................................................................3137 Hydraulic System................................................................3137 Safety Precautions Maintenance and Repair.......................................3138 General.........................................................................3141 Discharging the Capacitors..................................................3141 Hydraulic Pump and Motor........................................................3142 Remove......................................................................3142 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................3142 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................3145 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3148 Disassemble.................................................................3151 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........3151 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3153 Inspect.....................................................................3153 Clean.......................................................................3153 Assemble....................................................................3155 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........3155 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3155 Install.....................................................................3155 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................3155 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................3156 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3157 Hydraulic Tank for Lift Truck ..................................................3158 Remove......................................................................3158 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................3158 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................3161 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3163 Disassemble.................................................................3164 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................3164 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................3165 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3166 Clean.......................................................................3168 Steam Method............................................................3168 Chemical Method.........................................................3168 Inspect.....................................................................3168 Small Leaks, Repair.....................................................3169 Large Leaks, Repair.....................................................3169 Additional Methods for Metal Tank Repair................................3169 Assemble....................................................................3169 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................3169 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................3170 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3170 Install.....................................................................3171 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................3171 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................3171 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3171 Hydraulic Filter Replacement................................................3172 Breather Clean and Inspect..................................................3173 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........3173 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3176 Add Hydraulic Oil...........................................................3176 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)..........................3176 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)..........................3178 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................3178 Steer Accumulator Replacement...................................................3179 Remove......................................................................3179 Install.....................................................................3181 Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268)......................3182 Tank Capacity...............................................................3182 Specifications for Lift Truck E1.6-2.0XN (E30-40XN) (A269)......................3182 Tank Capacity...............................................................3182 Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276)......................3183 Tank Capacity...............................................................3183 Torque Specifications for Lift Truck E2.2-3.5XN (E45-70XN) (A268................3183 Hydraulic Pump and Motor....................................................3183 Hydraulic Tank..............................................................3183 Torque Specifications for Lift Truck E1.6-2.0XN (E30-40XN) (A269................3184 Hydraulic Pump and Motor....................................................3184 Hydraulic Tank..............................................................3184 Torque Specifications for Lift Truck J2.2-3.5XN (J45-70XN) (A276................3184 Hydraulic Pump and Motor....................................................3184 Hydraulic Tank..............................................................3184 tables..............................................................................3137 Table 1. Hydraulic Pump Motor...................................................3182 Table 2. Hydraulic Pump Motor...................................................3182 Table 3. Hydraulic Pump Motor...................................................3183 PM......................................................................................3187 toc.................................................................................3187 Periodic Maintenance............................................................3187 Safety Precautions Maintenance and Repair.......................................3188 General.........................................................................3193 Serial Number Data..........................................................3193 Discharging the Capacitors..................................................3193 How to Move Disabled Lift Truck.............................................3194 How to Tow Lift Truck...................................................3194 How to Put Lift Truck on Blocks.............................................3195 How to Raise Drive Tires................................................3195 How to Raise Steering Tires.............................................3195 How to Clean a Lift Truck...................................................3196 Safety Procedures When Working Near Mast........................................3197 WHEN WORKING NEAR THE MAST ALWAYS:..........................................3197 Maintenance Schedule............................................................3199 Maintenance Procedures Every 8 Hours or Daily...................................3203 How to Make Checks With Key or Keyless Switch OFF...........................3203 Tires and Wheels........................................................3203 Forks...................................................................3203 General.............................................................3203 Inspect.............................................................3204 Inspection of Mast, Carriage, Header Hoses, Lift Chains, and Att........3204 Safety Labels...........................................................3205 Steering Column Adjustments.............................................3206 Tilt Adjust Feature.................................................3206 Tilt Memory Feature.................................................3206 Telescopic Feature..................................................3206 Operator Restraint System...............................................3206 Emergency Locking Retractor (ELR).......................................3207 Battery Restraint System................................................3208 Battery.................................................................3211 Hydraulic System........................................................3212 How to Make Checks With Key or Keyless Switch ON............................3214 Horn, Lights, and Backup Alarm..........................................3214 Motion Alarm............................................................3214 Steering System.........................................................3214 Service Brakes..........................................................3214 Parking Brake...........................................................3215 Hydraulic Control Levers and Pedals.....................................3215 Direction and Speed Control Pedals......................................3215 Lift System Operation...................................................3215 Oil Leaks...............................................................3215 Maintenance Procedures Every 500 Hours or Three Months..........................3216 Forks.......................................................................3216 Remove..................................................................3216 Inspect.................................................................3217 Install.................................................................3217 Adjustment..............................................................3217 Header Hose Checks..........................................................3217 Mast Lubrication............................................................3218 Parking Brake Adjustment....................................................3221 Brake Fluid Check...........................................................3222 Master Cylinder Fluid Check.............................................3222 Operator Presence System Check..............................................3224 Differential and Speed Reducer..............................................3224 Tilt Cylinder Rod End Pins..................................................3226 Lift Chains.................................................................3226 Wear Check..............................................................3226 Lift Chain Lubrication......................................................3227 Fork Pins and Guides........................................................3227 Check Upper and Lower Bearings, Integral Sideshift Carriage.................3228 Check Lower Mounting Hook, Integral Sideshift Carriage......................3228 Steering King Pins..........................................................3229 Hydraulic Tank Breather, Check..............................................3229 Other Lubrication...........................................................3231 Contactor...................................................................3231 Maintenance Procedures Every 2000 Hours or Yearly...............................3232 Hydraulic System............................................................3232 Hydraulic Filter Element, Replace.......................................3232 Hydraulic Tank Breather, Change.........................................3234 Differential and Speed Reducer Oil Change...................................3236 Brake Fluid Replacement.....................................................3238 Service Brakes..............................................................3238 Forks.......................................................................3239 Integral Sideshift Carriage, Replace Upper and Lower Bearings...............3239 Lift Chains.................................................................3239 Wheel Bearings..............................................................3239 Steer Wheels, Lubrication...............................................3239 Drive Wheels, Lubrication...............................................3239 Maintenance Procedures Every 4000 Hours or Two Years............................3240 Hydraulic Oil, Change.......................................................3240 Steering Direction Sensor Inspection........................................3242 Fixed Steering Column...................................................3242 Telescopic Steering Column..............................................3243 Telescopic Steering Column Lubrication......................................3244 Battery Maintenance.............................................................3245 How to Charge Battery.......................................................3245 How to Change Batteries.....................................................3246 General.................................................................3246 Remove the Battery......................................................3246 Install the Battery.....................................................3251 Lift and Tilt System Leak Check.................................................3252 Lift Cylinders Leak Check...................................................3252 Tilt Cylinder Leak Check....................................................3252 Lift Chain Adjustments..........................................................3252 Welding Repairs.................................................................3254 Overhead Guard Changes..........................................................3254 Wheels and Tires................................................................3255 General.....................................................................3255 Remove Wheels From Lift Truck...............................................3255 Remove and Install Tire on Wheel............................................3255 Adhesives and Sealants..........................................................3256 tables..............................................................................3187 Table 1. Maintenance Schedule...................................................3200 Table 2. Hook-Type Carriage Chain Adjustment....................................3253 Specs...................................................................................3259 toc.................................................................................3259 Capacities and Specifications...................................................3259 Safety Precautions Maintenance and Repair.......................................3260 Counterweights..................................................................3263 Hydraulic System................................................................3263 Steering System.................................................................3264 Specifications..............................................................3264 Turning Radius..............................................................3264 Wheels and Tires................................................................3265 Battery Specifications..........................................................3266 Capacities......................................................................3267 Tilt Angles.....................................................................3267 Drift Rates (Maximum) for Tilt Cylinders........................................3268 Mast Speeds.....................................................................3268 Torque Specifications...........................................................3275 Frame.......................................................................3275 Drive Axle..................................................................3275 Differential and Speed Reducer..............................................3275 Brake System................................................................3275 Steering Axle...............................................................3276 Masts.......................................................................3276 Tilt Cylinders..............................................................3276 Hydraulic Pump and Motor....................................................3276 Hydraulic Tank..............................................................3277 Hydraulic Control Valves....................................................3277 Manual Valve............................................................3277 Manual Handles and Levers...............................................3277 Manual Valve Covers.....................................................3277 E-Hydraulic Valve.......................................................3277 Electrical System...........................................................3278 Adhesives and Sealants..........................................................3278 tables..............................................................................3259 Table 1. Manual Hydraulic Control Valve.........................................3263 Table 2. E-Hydraulic Control Valve..............................................3263 Table 3. Lift/Lower Speed, Standard Performance, 36 Volts.......................3268 Table 4. Lift/Lower Speed, Standard Performance, 48 Volts.......................3270 Table 5. Lift/Lower Speed Enhanced Performance, 48 Volts........................3271 Table 6. Lift/Lower Speed, Enhanced Performance, 80 Volts.......................3273 Steer Axle..............................................................................3281 toc.................................................................................3281 Steering Axle...................................................................3281 Safety Precautions Maintenance and Repair.......................................3282 General.........................................................................3285 Steering Axle Assembly Repair...................................................3286 Remove E2.2-3.5XN (E40-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A............3286 Disassemble.................................................................3287 Clean.......................................................................3288 Inspect.....................................................................3289 Assemble....................................................................3290 Install E2.2-3.5 (E40-70) (A268)............................................3290 Install E1.6-2.0XN (E30-40XN) (A269) .......................................3291 Remove J2.2-3.5XN (J45-70XN) (A276).........................................3292 Disassemble.................................................................3293 Clean.......................................................................3295 Inspect.....................................................................3295 Assemble....................................................................3295 Install.....................................................................3296 Remove J1.6-2.0XN (J30-40XN) (A935).........................................3297 Disassemble.................................................................3297 Clean.......................................................................3299 Inspect.....................................................................3299 Assemble....................................................................3299 Install.....................................................................3300 Tie Rod Replacement.............................................................3301 Remove E2.2-E3.5XN (E45-70XN) (A268)........................................3301 Clean.......................................................................3301 Inspect.....................................................................3301 Install.....................................................................3302 Remove E1.6-2.0XN (E30-40XN) (A269).........................................3302 Clean.......................................................................3303 Inspect.....................................................................3303 Install.....................................................................3303 Remove J2.0-3.5XN (J45-70XN) (A276).........................................3303 Clean.......................................................................3303 Inspect.....................................................................3304 Install.....................................................................3304 Remove J1.6-2.0XN (J30-40XN) (A935).........................................3304 Clean.......................................................................3305 Inspect.....................................................................3305 Install.....................................................................3305 Spindle Repair..................................................................3305 Remove E2.2-3.5XN (E40-70XN) (A268).........................................3305 Disassemble.................................................................3307 Clean.......................................................................3307 Inspect.....................................................................3307 Assemble....................................................................3307 Install.....................................................................3308 Remove E1.6-2.0XN (E30-40XN) (A269).........................................3309 Disassemble.................................................................3309 Clean.......................................................................3310 Inspect.....................................................................3310 Assemble....................................................................3310 Install.....................................................................3311 Remove J2.2-3.5XN (J45-70XN) (A276).........................................3311 Disassemble.................................................................3312 Clean.......................................................................3312 Inspect.....................................................................3312 Assemble....................................................................3313 Install.....................................................................3313 Remove J1.6-2.0XN (J30-40XN) (A935).........................................3314 Disassemble.................................................................3314 Clean.......................................................................3316 Inspect.....................................................................3316 Assemble....................................................................3316 Install.....................................................................3316 Steering Cylinder Repair........................................................3317 Remove E2.2-E3.5XN (E45XN-70XN) (A268) and J2.2-3.5XN (J45-70XN)............3317 Disassemble.................................................................3318 Clean.......................................................................3319 Inspect.....................................................................3320 Assemble....................................................................3320 Install.....................................................................3320 Remove E1.6-2.0XN (E30-40XN) (A269).........................................3320 Disassemble ................................................................3321 Clean.......................................................................3322 Inspect.....................................................................3323 Assemble....................................................................3323 Install.....................................................................3323 Remove J1.6-2.0XN (J30-40XN) (A935).........................................3323 Disassemble.................................................................3324 Clean.......................................................................3325 Inspect.....................................................................3325 Assemble....................................................................3325 Install.....................................................................3326 Steer System............................................................................3329 toc.................................................................................3329 Steering System.................................................................3329 Safety Precautions Maintenance and Repair.......................................3330 General.........................................................................3333 Discharging The Capacitors..................................................3333 Steering Control Unit (SCU) Repair..............................................3334 Remove......................................................................3334 Disassemble.................................................................3336 Clean.......................................................................3338 Inspect.....................................................................3338 Assemble....................................................................3338 Install.....................................................................3339 Steering Wheel and Fixed Steering Column Assembly Repair........................3340 Remove......................................................................3340 Disassemble.................................................................3342 Clean.......................................................................3344 Inspect.....................................................................3344 Assemble....................................................................3344 Install.....................................................................3345 Fixed Steering Column Gear Replacement......................................3346 Steering Wheel and Telescopic Column Assembly Repair............................3347 Remove......................................................................3347 Disassemble.................................................................3349 Clean.......................................................................3353 Inspect.....................................................................3353 Assemble....................................................................3354 Install.....................................................................3355 Telescopic Steering Column Gear Replacement.................................3356 Torque Specifications...........................................................3361 Steering Control Unit.......................................................3361 Steering Column.............................................................3361 User Int. Sup...........................................................................3365 toc.................................................................................3365 User Interface..................................................................3365 Safety Precautions Maintenance and Repair.......................................3366 General.........................................................................3371 Description.................................................................3371 Display Panel Menu Access...................................................3371 Menu Flowchart..................................................................3372 Supervisor Menu Flowchart...................................................3372 Menu Navigation.................................................................3378 Main Menu Structure.........................................................3378 Screens and Title Screens...................................................3378 Submenus....................................................................3379 Returning to the Main Menu..................................................3380 Icons and Settings..........................................................3380 Soft Keys...................................................................3380 Entering Numbers............................................................3381 Icon Glossary...................................................................3381 Introduction................................................................3381 Soft Key Icons..............................................................3381 Overlay Icons...............................................................3383 Icons on System Off Screen and Alert Screens................................3383 Main Menu Title Screens.....................................................3386 Submenu Icons Grouped by Menu...............................................3388 Operating Screen Icons..................................................3388 Password Screen Icons...................................................3389 Activity Log Submenu Icons..............................................3389 Calibration Submenu Icons...............................................3391 Display Submenu Icons...................................................3394 Status Submenu Icons....................................................3396 Truck Setup Submenu Icons...............................................3399 Operating Screen................................................................3405 Introduction................................................................3405 Performance Mode Controls...................................................3405 Status and Warning Icons....................................................3406 Battery Discharge Indicator.................................................3407 Direction and Parking Brake Indicators......................................3407 Hazard Flashers and Lighting Controls.......................................3408 Tire Angle Indicator........................................................3408 System Time.................................................................3408 Load Weight Indicator.......................................................3408 System Off/Alert Screens........................................................3408 Introduction................................................................3408 System Off Screen...........................................................3408 Alert Screens...............................................................3409 Password Screen.................................................................3410 Introduction................................................................3410 Password Screen.............................................................3410 Service Technician Password Setup.......................................3411 Adding/Removing/Changing Passwords..........................................3412 Password Log................................................................3415 Activity Log Menu...............................................................3415 Introduction................................................................3415 Operator Checklist Log......................................................3416 Password Log................................................................3418 Impact Events Log...........................................................3419 Calibration Menu................................................................3421 Introduction................................................................3421 Load Weight Calibration.....................................................3421 Return to Set Tilt Stop Point Calibration...................................3422 E-Hydraulic and Manual Valve Threshold Calibration..........................3422 Steering Wheel Knob Center Point Calibration................................3423 Steer Axle Position Calibration.............................................3423 Manual Hydraulics Calibration...............................................3424 Display Menu....................................................................3424 Introduction................................................................3424 Set Date and Time Format Menu...............................................3425 Set Daylight Saving Time Menu...............................................3426 Procedure for Setting Up Automatic Daylight Savings Time................3427 Set Time and Date Menu......................................................3429 Procedure for Setting Time and Date.....................................3430 Set Units Menu..............................................................3430 Status Menu.....................................................................3431 Introduction................................................................3431 VSM Versions................................................................3431 Display Versions............................................................3432 Truck Serial Number.........................................................3432 Hour Meters.................................................................3432 E-Hydraulic Controller Versions.............................................3432 Pump Motor Controller Versions..............................................3432 Traction Motor Controller 1 Versions........................................3433 Traction Motor Controller 2 Versions........................................3433 Light Controller Versions...................................................3433 Impact Sensor Versions......................................................3433 Truck Setup Menu................................................................3433 Introduction................................................................3433 Add/Remove Password.........................................................3434 Restore Default Settings....................................................3434 Motion Alarm................................................................3434 Impact Monitor Settings.....................................................3435 Impact Detection........................................................3435 Setting Adjustments.....................................................3435 Initial Adjustment of Soft and Hard Impact Settings.....................3435 Readjustment of Soft and Hard Impact Settings...........................3436 Auto Power-Off Time Delay...................................................3436 Return to Set Tilt..........................................................3436 Traction Speed Limit........................................................3437 Scheduled Maintenance Reminder..............................................3437 Minimum Pump Standby Flow Rate..............................................3438 Operator Checklist..........................................................3438 Impact Monitor Shutdown.....................................................3439 Motor Braking...............................................................3440 Changing the Motor Braking Settings.....................................3440 tables..............................................................................3365 Table 1. Supervisor Menu Flowchart..............................................3377 Table 2. Soft Key Icons.........................................................3382 Table 3. Overlay Icons..........................................................3383 Table 4. Alert Screen Icons.....................................................3383 Table 5. Main Menu Title Screens................................................3386 Table 6. Operating Screen Icons.................................................3388 Table 7. Password Screen Icons..................................................3389 Table 8. Activity Log Submenus and Icons........................................3389 Table 9. Calibration Submenus and Icons.........................................3391 Table 10. Display Submenus and Icons............................................3394 Table 11. Status Submenus and Icons.............................................3396 Table 12. Truck Setup Submenu Icons.............................................3399 Table 13. BSOC in Relation to BDI...............................................3407 Table 14. Add Password..........................................................3412 Table 15. Change or Remove Password.............................................3414 Table 16. Access Operator Checklist Log Screens.................................3417 Table 17. Access Password Log Screens...........................................3419 Table 18. Access Impact Events Log Screens......................................3420 Table 19. Accessing the Set Date and Time Format Screen.........................3426 Table 20. Set Daylight Saving Time Menu.........................................3428 User Int. Tech..........................................................................3443 toc.................................................................................3443 User Interface..................................................................3443 Safety Precautions Maintenance and Repair.......................................3444 General.........................................................................3449 Description.................................................................3449 Display Panel Menu Access...................................................3449 Menu Flowchart..................................................................3450 Technician Menu Flowchart...................................................3450 Menu Navigation.................................................................3456 Main Menu Structure.........................................................3456 Screens and Title Screens...................................................3456 Submenus....................................................................3457 Returning to the Main Menu..................................................3458 Icons and Settings..........................................................3458 Soft Keys...................................................................3458 Entering Numbers............................................................3459 Icon Glossary...................................................................3459 Introduction................................................................3459 Soft Key Icons..............................................................3459 Overlay Icons...............................................................3461 System Off Screen and Alert Screens.........................................3461 Main Menu Title Screens.....................................................3464 Submenu Icons Grouped by Menu...............................................3466 Operating Screen Icons..................................................3466 Password Screen Icons...................................................3467 Activity Log Submenu Icons..............................................3467 Calibration Submenu Icons...............................................3468 Display Submenu Icons...................................................3471 Status Submenu Icons....................................................3473 Truck Setup Submenu Icons...............................................3477 Diagnostics Submenu Icons...............................................3489 Operating Screen................................................................3496 Introduction................................................................3496 Performance Mode Controls...................................................3497 Status and Warning Icons....................................................3498 Battery Discharge Indicator.................................................3498 Direction and Parking Brake Indicators......................................3499 Hazard Flashers and Lighting Controls.......................................3499 Tire Angle Indicator........................................................3499 System Time.................................................................3500 Load Weight Indicator.......................................................3500 System Off/Alert Screens........................................................3500 Introduction................................................................3500 System Off Screen...........................................................3500 Alert Screens...............................................................3501 Password Screen.................................................................3502 Introduction................................................................3502 Password Screen.............................................................3502 Service Technician Password Setup.......................................3503 Adding/Removing/Changing Passwords..........................................3504 Password Log................................................................3505 Activity Log Menu...............................................................3507 Introduction................................................................3507 Operator Checklist Log......................................................3508 Password Log................................................................3510 Impact Events Log...........................................................3511 Calibration Menu................................................................3513 Introduction................................................................3513 Load Weight Calibration.....................................................3513 Return to Set Tilt Stop Point Calibration...................................3514 E-Hydraulic and Manual Valve Threshold Calibration..........................3514 Steering Wheel Knob Center Point Calibration................................3515 Steer Axle Position Calibration.............................................3516 Manual Hydraulics Calibration...............................................3516 Display Menu....................................................................3517 Introduction................................................................3517 Set Date and Time Format Menu...............................................3517 Set Daylight Saving Time Menu...............................................3519 Procedure for Setting Up Automatic Daylight Savings Time................3519 Set Time and Date Menu......................................................3521 Procedure for Setting Time and Date.....................................3522 Set Units Menu..............................................................3522 Status Menu.....................................................................3523 Introduction................................................................3523 VSM Versions................................................................3523 Display Versions............................................................3524 Truck Serial Number.........................................................3524 Hour Meters.................................................................3524 E-Hydraulic Controller Versions.............................................3524 Pump Motor Controller Versions..............................................3524 Traction Motor Controller 1 Versions........................................3525 Traction Motor Controller 2 Versions........................................3525 Light Controller Versions...................................................3525 Impact Sensor Versions......................................................3525 Truck Setup Menu................................................................3525 Introduction................................................................3525 Add/Remove Password.........................................................3526 Motor Braking...............................................................3526 Changing the Motor Braking Settings.....................................3527 Battery Setup...............................................................3527 BDI Adjustment Setting......................................................3529 Acceleration Rates..........................................................3529 Hour Meter Initialization...................................................3530 Impact Monitor Shutdown.....................................................3530 Operator Checklist..........................................................3531 Minimum Pump Standby Flow Rate..............................................3531 Scheduled Maintenance Reminder..............................................3532 Traction Speed Limit........................................................3533 Return to Set Tilt..........................................................3533 Auto Power-Off Time Delay...................................................3534 Impact Monitor Settings.....................................................3534 Impact Detection........................................................3534 Setting Adjustments.....................................................3535 Initial Adjustment of Soft and Hard Impact Settings.....................3535 Readjustment of Soft and Hard Impact Settings...........................3535 Motion Alarm................................................................3535 Lift Hydraulic Function Maximum Speed and Ramp Times........................3536 Lower Hydraulic Function Maximum Speed and Ramp Times.......................3536 Tilt Forward Hydraulic Function Maximum Speed and Ramp Times................3536 Tilt Backward Hydraulic Function Maximum Speed and Ramp Times...............3537 Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times................3537 Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times................3537 Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times................3537 Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times................3537 Optional Hydraulic Functions................................................3537 Rear Lights Control.........................................................3538 Restore Default Settings....................................................3538 Diagnostics Menu................................................................3539 Introduction................................................................3539 Fault Code Log..............................................................3539 Fault Log Details.......................................................3540 Speedometer.................................................................3541 Direction Switch............................................................3541 Traction Motor 1 Status.....................................................3541 Traction Motor 2 Status.....................................................3542 Occupancy Sensor............................................................3542 Brake System Sensors........................................................3542 Pump Status.................................................................3542 Hydraulic Control Inputs....................................................3543 E-Hydraulic Valves..........................................................3543 Hydraulic Sensors...........................................................3544 System Voltages.............................................................3544 Steering Position Sensors...................................................3545 tables..............................................................................3443 Table 1. Technician Menu Flowchart..............................................3455 Table 2. Soft Key Icons.........................................................3460 Table 3. Overlay Icons..........................................................3461 Table 4. Alert Screen Icons.....................................................3461 Table 5. Main Menu Title Screens................................................3464 Table 6. Operating Screen Icons.................................................3466 Table 7. Password Screen Icons..................................................3467 Table 8. Activity Log Submenus and Icons........................................3467 Table 9. Calibration Submenus and Icons.........................................3469 Table 10. Display Submenus and Icons............................................3471 Table 11. Status Submenus and Icons.............................................3473 Table 12. Truck Setup Submenu Icons.............................................3477 Table 13. Diagnostic Submenu Icons..............................................3489 Table 14. BSOC in Relation to BDI...............................................3499 Table 15. Add Password..........................................................3504 Table 16. Change or Remove Password.............................................3506 Table 17. Access Operator Checklist Log Screens.................................3509 Table 18. Access Password Log Screens...........................................3511 Table 19. Access Impact Events Log Screens......................................3512 Table 20. Accessing the Set Date and Time Format Screen.........................3518 Table 21. Set Daylight Saving Time Menu.........................................3520 Table 22. Battery Setup Factory Defaults........................................3528 Binder2.....................................................................................3549 Hyster-E45Xn,50,55,60,65,70-899648-2240SRM0001-(02-2008)-US-EN..........................3549 toc.................................................................................3549 Industrial Battery..............................................................3549 Safety Precautions Maintenance and Repair.......................................3550 General.........................................................................3553 Lead-Acid Batteries.............................................................3553 Specific Gravity................................................................3554 Chemical Reaction in a Cell.....................................................3554 Electrical Terms................................................................3555 Battery Selection...............................................................3556 Battery Voltage.................................................................3557 Battery as a Counterweight......................................................3557 Battery Ratings.................................................................3558 Kilowatt-Hours..............................................................3558 Battery Maintenance.............................................................3558 Safety Procedures...........................................................3558 Maintenance Records.........................................................3559 New Battery.................................................................3559 Cleaning Battery............................................................3559 Adding Water to Battery.....................................................3561 Hydrometer..................................................................3562 Battery Temperature.........................................................3562 Charging Battery............................................................3563 Types of Battery Charges................................................3564 Methods of Charging.....................................................3565 Troubleshooting Charger.................................................3566 Knowing When Battery Is Fully Charged...................................3566 Where to Charge Batteries...................................................3566 Equipment Needed........................................................3566 Battery Connectors..........................................................3567 Battery Care................................................................3567 tables..............................................................................3549 Table 1. Battery Capacity Terms.................................................3558 Hyster-E45Xn,50,55,60,65,70-1580517-2200SRM1128-(01-2012)-US-EN.........................3571 toc.................................................................................3571 Wire Harness Repair.............................................................3571 Safety Precautions Maintenance and Repair.......................................3572 General.........................................................................3577 Deutsch Crimping Tool...........................................................3577 How to Strip a Wire for Use With Deutsch Crimping Tool......................3577 How to Crimp With the Deutsch Crimping Tool.................................3578 Calibration Test for the Deutsch Crimping Tool..............................3580 Deutsch Connectors..............................................................3581 DT, DTM, and DTP Series Connectors..........................................3581 Connector Receptacle Replacement........................................3590 Connector Plug Replacement..............................................3598 Connector Receptacle Pin Replacement....................................3606 Connector Plug Socket Replacement.......................................3615 HD Series Connectors........................................................3624 Connector Receptacle Replacement........................................3626 Connector Plug Replacement..............................................3630 Connector Receptacle Pin Replacement....................................3633 Connector Plug Socket Replacement.......................................3639 Sealing Plugs...............................................................3643 Metri-Pack Connectors...........................................................3645 Remove and Install..........................................................3645 Micro-Pack Connectors...........................................................3647 Weather-Pack Connectors.........................................................3648 Weather-Pack Terminal Repair................................................3648 AMPSEAL Crimping Tools..........................................................3650 AMP Hand Crimping Tool With Certi-Crimp.....................................3650 Description.............................................................3650 Stripping Wire for Use with AMP Hand Crimping Tool......................3651 Insulation Crimp Adjustment.............................................3651 Maintenance and Inspection for AMP Hand Crimping Tool...................3652 AMP Hand Crimping Tool..............................................3652 Crimp Height Inspection.............................................3652 How to use AMP Hand Crimping Tool...........................................3653 AMP Pro-Crimper II Tool.....................................................3653 Description.............................................................3653 Remove and Install Die Set and Locator Assembly.....................3654 Stripping Wire for Use With AMP PRO-CRIMPER II Tool.....................3654 Contact Support Adjustment..............................................3655 Crimp Height Adjustment.................................................3655 Maintenance and Inspection Procedures...................................3656 PRO-CRIMPER II Tool.................................................3656 Crimp Height Inspection.............................................3656 How to Use AMP PRO-CRIMPER II Tool..........................................3657 AMPSEAL Connector Assemblies....................................................3658 Description for Plug Connector Assembly.....................................3658 Seal Plug...............................................................3658 Contact Crimping........................................................3659 Contact Removal.........................................................3659 Contact Insertion.......................................................3661 Description for Plug Connector and Header Assembly..........................3663 Voltage Reading.........................................................3666 Seal Plug...............................................................3666 Contact Crimping........................................................3666 Contact Removal.........................................................3669 Contact Insertion.......................................................3671 AMP Superseal 1.5 Crimping Tools................................................3673 Mini Mic Receptacle and Tab Contacts........................................3673 Description.............................................................3673 Crimping Conditions and Measurements....................................3673 Insertion of Rubber Seal on Cable.......................................3675 Correction or Replacement of Parts......................................3676 AMP Hand Application Tool...................................................3679 Description.............................................................3679 Maintenance and Inspection..............................................3680 Crimp Height Inspection.............................................3680 Crimp Height Adjustment.................................................3681 How to Use AMP Hand Application Tool........................................3681 AMP Pro-Crimper II Tool.....................................................3682 Description.............................................................3682 Remove and Install Die Set and Locator Assembly.....................3683 Adjustments.............................................................3683 Contact Support.....................................................3683 Crimp Height........................................................3684 Inspections and Maintenance.............................................3685 Crimp Height Inspection.............................................3685 Visual Inspection...................................................3685 Maintenance.........................................................3685 How to Use Pro-Crimper II Tool..............................................3686 AMP Superseal 1.5 Connector Assemblies..........................................3687 Description.................................................................3687 Harness Assembly........................................................3687 Positioning of Anti-Backout Device..................................3688 Removal of Contacts.................................................3690 Repair and Maintenance......................................................3694 Panel Mount Option..........................................................3694 AMP Fastin-Faston Hand Tools....................................................3695 Description - AMP Double Action Hand Tool...................................3695 Maintenance and Inspection Procedures.......................................3696 Daily Maintenance.......................................................3696 Periodic Tool Inspection................................................3696 Lubrication.........................................................3696 Visual Inspection...................................................3696 Crimp Height Inspection.................................................3697 Certi-Crimp Ratchet Inspection..........................................3697 How to Use AMP Double Action Hand Tool......................................3698 Description - AMP Extraction Tool...........................................3699 Maintenance and Inspection..................................................3699 How to Use AMP Extraction Tool..............................................3700 AMP Fastin-Faston Receptacles and Housings......................................3701 Description.................................................................3701 Wire Repair.....................................................................3708 Wire Splicing Requirements..................................................3708 Deutsch Jiffy Splice........................................................3709 Assemble................................................................3709 Disassemble.............................................................3711 Del-City Crimp-Solder-Shrink Splice.........................................3713 Twisted/Shielded Cable and Leads Repair.........................................3714 Twisted/Shielded Cable Repair...............................................3714 Twisted Leads Repair........................................................3716 Special Tools...................................................................3717 tables..............................................................................3571 Table 1. Wire Strip Length Specifications.......................................3577 Table 2. Wire Size (AWG)........................................................3651 Table 3. Crimp Height...........................................................3652 Table 4. Strip Length for PRO-CRIMPER II Tool...................................3655 Table 5. Crimp Measurement......................................................3656 Table 6. Current Rating.........................................................3658 Table 7. Crimp Conditions.......................................................3667 Table 8. Wire Strip Lengths.....................................................3680 Table 9. Wire Strip Lengths.....................................................3681 Table 10. Crimp Height - Dimension .............................................3685 Table 11. Wire Size and Crimp Height............................................3697 Table 12. Wire Strip Length.....................................................3698 Table 13. Wire Strip Length and Crimp Measurements..............................3703 Table 14. Crimp Pull-Out Test...................................................3707 Table 15. Wire Strip Length Specifications......................................3708 Table 16. Wire Splice Size......................................................3713 Hyster-E45Xn,50,55,60,65,70-Operators-CAB-4025482-0100SRM1446-(08-2011)-US-EN...........3727 toc.................................................................................3727 Operator's Cab..................................................................3727 Safety Precautions Maintenance and Repair.......................................3728 Window Replacement..............................................................3731 Front Panel.................................................................3731 Remove..................................................................3731 Clean...................................................................3731 Inspect.................................................................3732 Install.................................................................3732 Rear Panel..................................................................3732 Remove..................................................................3732 Clean...................................................................3735 Inspect.................................................................3735 Install.................................................................3735 Door Window.................................................................3736 Disassemble Window......................................................3736 Clean...................................................................3737 Inspect.................................................................3737 Assemble Window.........................................................3737 Window Wipers Replacement.......................................................3737 Front Wiper Assembly........................................................3737 Remove..................................................................3737 Clean...................................................................3741 Inspect.................................................................3741 Install.................................................................3741 Cab Component Repair............................................................3742 Roof Liner..................................................................3742 Remove..................................................................3742 Clean...................................................................3743 Inspect.................................................................3743 Install.................................................................3743 Top Panel...................................................................3743 Remove..................................................................3743 Clean...................................................................3745 Inspect.................................................................3745 Install.................................................................3745 Cab Door Assembly...............................................................3746 Door Assembly...............................................................3746 Remove..................................................................3746 Disassemble Left Door...................................................3749 Disassemble Right Door..................................................3751 Clean...................................................................3751 Inspect.................................................................3751 Assemble Right Door.....................................................3753 Assemble Left Door......................................................3753 Install.................................................................3753 Cab Heater......................................................................3754 Cab Heater..................................................................3754 Remove..................................................................3754 Clean...................................................................3754 Inspect.................................................................3754 Install.................................................................3757 Troubleshooting.........................................................3757 Weather Panel Replacement for Lift Truck Model E2.2-3.5XN (E45-7................3760 Remove......................................................................3760 Roof Panels.............................................................3760 Front Screen Panel......................................................3760 Install.....................................................................3762 Front Screen Panel......................................................3762 Roof Panels.............................................................3763 tables..............................................................................3727 Table 1. Connector C1...........................................................3759 Table 2. Connector C2...........................................................3759 Table 3. Connector C3...........................................................3759 Table 4. Connector C4...........................................................3759 Table 5. Connector C5...........................................................3759 Table 6. Connector C6...........................................................3759 Table 7. Connector C7...........................................................3759 Hyster-E45Xn,50,55,60,65,70-Steering-System-1688873-1600SRM1363-(11-2010)-US-EN.........3767 toc.................................................................................3767 Steering System.................................................................3767 Safety Precautions Maintenance and Repair.......................................3768 General.........................................................................3771 Discharging The Capacitors..................................................3771 Steering Control Unit (SCU) Repair..............................................3772 Remove......................................................................3772 Disassemble.................................................................3774 Clean.......................................................................3776 Inspect.....................................................................3776 Assemble....................................................................3776 Install.....................................................................3777 Steering Wheel and Fixed Steering Column Assembly Repair........................3778 Remove......................................................................3778 Disassemble.................................................................3780 Clean.......................................................................3782 Inspect.....................................................................3782 Assemble....................................................................3782 Install.....................................................................3783 Fixed Steering Column Gear Replacement......................................3784 Steering Wheel and Telescopic Column Assembly Repair............................3785 Remove......................................................................3785 Disassemble.................................................................3787 Clean.......................................................................3791 Inspect.....................................................................3791 Assemble....................................................................3792 Install.....................................................................3793 Telescopic Steering Column Gear Replacement.................................3794 Torque Specifications...........................................................3799 Steering Control Unit.......................................................3799 Steering Column.............................................................3799 Hyster-E45Xn,50,55,60,65,70-User-Interface-1688878-2200SRM1335-(12-2011)-US-EN..........3803 toc.................................................................................3803 User Interface..................................................................3803 Safety Precautions Maintenance and Repair.......................................3804 General.........................................................................3809 Description.................................................................3809 Display Panel Menu Access...................................................3809 Menu Flowchart..................................................................3810 Supervisor Menu Flowchart...................................................3810 Menu Navigation.................................................................3816 Main Menu Structure.........................................................3816 Screens and Title Screens...................................................3817 Submenus....................................................................3817 Returning to the Main Menu..................................................3818 Icons and Settings..........................................................3818 Soft Keys...................................................................3818 Entering Numbers............................................................3819 Icon Glossary...................................................................3819 Introduction................................................................3819 Soft Key Icons..............................................................3819 Overlay Icons...............................................................3821 Icons on System Off Screen and Alert Screens................................3821 Main Menu Title Screens.....................................................3824 Submenu Icons Grouped by Menu...............................................3826 Operating Screen Icons..................................................3826 Password Screen Icons...................................................3827 Activity Log Submenu Icons..............................................3828 Calibration Submenu Icons...............................................3829 Display Submenu Icons...................................................3832 Status Submenu Icons....................................................3834 Truck Setup Submenu Icons...............................................3837 Operating Screen................................................................3843 Introduction................................................................3843 Performance Mode Controls...................................................3843 Status and Warning Icons....................................................3844 Battery Discharge Indicator.................................................3845 Direction and Parking Brake Indicators......................................3846 Hazard Flashers and Lighting Controls.......................................3846 Tire Angle Indicator........................................................3846 System Time.................................................................3846 Load Weight Indicator.......................................................3846 System Off/Alert Screens........................................................3846 Introduction................................................................3846 System Off Screen...........................................................3846 Alert Screens...............................................................3847 Password Screen.................................................................3848 Introduction................................................................3848 Password Screen.............................................................3848 Service Technician Password Setup.......................................3849 Adding/Removing/Changing Passwords..........................................3850 Password Log................................................................3854 Activity Log Menu...............................................................3854 Introduction................................................................3854 Operator Checklist Log......................................................3855 Password Log................................................................3857 Impact Events Log...........................................................3859 Calibration Menu................................................................3861 Introduction................................................................3861 Load Weight Calibration.....................................................3861 Return to Set Tilt Stop Point Calibration...................................3862 E-Hydraulic and Manual Valve Threshold Calibration..........................3862 Steering Wheel Knob Center Point Calibration................................3863 Steer Axle Position Calibration.............................................3864 Manual Hydraulics Calibration...............................................3864 Display Menu....................................................................3865 Introduction................................................................3865 Set Date and Time Format Menu...............................................3865 Set Daylight Saving Time Menu...............................................3867 Procedure for Setting Up Automatic Daylight Savings Time................3867 Set Time and Date Menu......................................................3869 Procedure for Setting Time and Date.....................................3870 Set Units Menu..............................................................3870 Status Menu.....................................................................3871 Introduction................................................................3871 VSM Versions................................................................3871 Display Versions............................................................3872 Truck Serial Number.........................................................3872 Hour Meters.................................................................3872 E-Hydraulic Controller Versions.............................................3872 Pump Motor Controller Versions..............................................3872 Traction Motor Controller 1 Versions........................................3873 Traction Motor Controller 2 Versions........................................3873 Light Controller Versions...................................................3873 Impact Sensor Versions......................................................3873 Truck Setup Menu................................................................3873 Introduction................................................................3873 Add/Remove Password.........................................................3874 Restore Default Settings....................................................3874 Motion Alarm................................................................3874 Impact Monitor Settings.....................................................3875 Impact Detection........................................................3875 Setting Adjustments.....................................................3875 Initial Adjustment of Soft and Hard Impact Settings.....................3876 Readjustment of Soft and Hard Impact Settings...........................3876 Auto Power-Off Time Delay...................................................3876 Return to Set Tilt..........................................................3877 Traction Speed Limit........................................................3877 Scheduled Maintenance Reminder..............................................3877 Minimum Pump Standby Flow Rate..............................................3878 Operator Checklist..........................................................3879 Impact Monitor Shutdown.....................................................3880 Motor Braking...............................................................3880 Changing the Motor Braking Settings.....................................3880 tables..............................................................................3803 Table 1. Supervisor Menu Flowchart..............................................3815 Table 2. Soft Key Icons.........................................................3820 Table 3. Overlay Icons..........................................................3821 Table 4. Alert Screen Icons.....................................................3821 Table 5. Main Menu Title Screens................................................3824 Table 6. Operating Screen Icons.................................................3826 Table 7. Password Screen Icons..................................................3827 Table 8. Activity Log Submenus and Icons........................................3828 Table 9. Calibration Submenus and Icons.........................................3829 Table 10. Display Submenus and Icons............................................3832 Table 11. Status Submenus and Icons.............................................3834 Table 12. Truck Setup Submenu Icons.............................................3837 Table 13. BSOC in Relation to BDI...............................................3845 Table 14. Add Password..........................................................3850 Table 15. Change or Remove Password.............................................3853 Table 16. Access Operator Checklist Log Screens.................................3856 Table 17. Access Password Log Screens...........................................3858 Table 18. Access Impact Events Log Screens......................................3860 Table 19. Accessing the Set Date and Time Format Screen.........................3866 Table 20. Set Daylight Saving Time Menu.........................................3868 Hyster-E45Xn,50,55,60,65,70-User-Interface-1688879-2200SRM1336-(12-2011)-US-EN..........3885 toc.................................................................................3885 User Interface..................................................................3885 Safety Precautions Maintenance and Repair.......................................3886 General.........................................................................3891 Description.................................................................3891 Display Panel Menu Access...................................................3891 Menu Flowchart..................................................................3892 Technician Menu Flowchart...................................................3892 Menu Navigation.................................................................3898 Main Menu Structure.........................................................3898 Screens and Title Screens...................................................3899 Submenus....................................................................3899 Returning to the Main Menu..................................................3900 Icons and Settings..........................................................3900 Soft Keys...................................................................3900 Entering Numbers............................................................3901 Icon Glossary...................................................................3901 Introduction................................................................3901 Soft Key Icons..............................................................3901 Overlay Icons...............................................................3903 System Off Screen and Alert Screens.........................................3903 Main Menu Title Screens.....................................................3906 Submenu Icons Grouped by Menu...............................................3908 Operating Screen Icons..................................................3908 Password Screen Icons...................................................3909 Activity Log Submenu Icons..............................................3909 Calibration Submenu Icons...............................................3911 Display Submenu Icons...................................................3914 Status Submenu Icons....................................................3916 Truck Setup Submenu Icons...............................................3919 Diagnostics Submenu Icons...............................................3931 Operating Screen................................................................3939 Introduction................................................................3939 Performance Mode Controls...................................................3940 Status and Warning Icons....................................................3940 Battery Discharge Indicator.................................................3941 Direction and Parking Brake Indicators......................................3942 Hazard Flashers and Lighting Controls.......................................3942 Tire Angle Indicator........................................................3942 System Time.................................................................3942 Load Weight Indicator.......................................................3942 System Off/Alert Screens........................................................3943 Introduction................................................................3943 System Off Screen...........................................................3943 Alert Screens...............................................................3943 Password Screen.................................................................3944 Introduction................................................................3944 Password Screen.............................................................3944 Service Technician Password Setup.......................................3945 Adding/Removing/Changing Passwords..........................................3946 Password Log................................................................3949 Activity Log Menu...............................................................3949 Introduction................................................................3949 Operator Checklist Log......................................................3950 Password Log................................................................3952 Impact Events Log...........................................................3954 Calibration Menu................................................................3956 Introduction................................................................3956 Load Weight Calibration.....................................................3956 Return to Set Tilt Stop Point Calibration...................................3956 E-Hydraulic and Manual Valve Threshold Calibration..........................3957 Steering Wheel Knob Center Point Calibration................................3958 Steer Axle Position Calibration.............................................3958 Manual Hydraulics Calibration...............................................3959 Display Menu....................................................................3960 Introduction................................................................3960 Set Date and Time Format Menu...............................................3960 Set Daylight Saving Time Menu...............................................3962 Procedure for Setting Up Automatic Daylight Savings Time................3962 Set Time and Date Menu......................................................3964 Procedure for Setting Time and Date.....................................3965 Set Units Menu..............................................................3965 Status Menu.....................................................................3966 Introduction................................................................3966 VSM Versions................................................................3966 Display Versions............................................................3967 Truck Serial Number.........................................................3967 Hour Meters.................................................................3967 E-Hydraulic Controller Versions.............................................3967 Pump Motor Controller Versions..............................................3967 Traction Motor Controller 1 Versions........................................3968 Traction Motor Controller 2 Versions........................................3968 Light Controller Versions...................................................3968 Impact Sensor Versions......................................................3968 Truck Setup Menu................................................................3968 Introduction................................................................3968 Add/Remove Password.........................................................3969 Motor Braking...............................................................3969 Changing the Motor Braking Settings.....................................3970 Battery Setup...............................................................3970 BDI Adjustment Setting......................................................3972 Acceleration Rates..........................................................3972 Hour Meter Initialization...................................................3973 Impact Monitor Shutdown.....................................................3973 Operator Checklist..........................................................3974 Minimum Pump Standby Flow Rate..............................................3974 Scheduled Maintenance Reminder..............................................3975 Traction Speed Limit........................................................3976 Return to Set Tilt..........................................................3976 Auto Power-Off Time Delay...................................................3977 Impact Monitor Settings.....................................................3977 Impact Detection........................................................3978 Setting Adjustments.....................................................3978 Initial Adjustment of Soft and Hard Impact Settings.....................3978 Readjustment of Soft and Hard Impact Settings...........................3978 Motion Alarm................................................................3978 Lift Hydraulic Function Maximum Speed and Ramp Times........................3979 Lower Hydraulic Function Maximum Speed and Ramp Times.......................3980 Tilt Forward Hydraulic Function Maximum Speed and Ramp Times................3980 Tilt Backward Hydraulic Function Maximum Speed and Ramp Times...............3980 Auxiliary 1A Hydraulic Function Maximum Speed and Ramp Times................3980 Auxiliary 1B Hydraulic Function Maximum Speed and Ramp Times................3980 Auxiliary 2A Hydraulic Function Maximum Speed and Ramp Times................3980 Auxiliary 2B Hydraulic Function Maximum Speed and Ramp Times................3981 Optional Hydraulic Functions................................................3981 Rear Lights Control.........................................................3981 Restore Default Settings....................................................3982 Diagnostics Menu................................................................3982 Introduction................................................................3982 Fault Code Log..............................................................3983 Fault Log Details.......................................................3983 Speedometer.................................................................3984 Direction Switch............................................................3984 Traction Motor 1 Status.....................................................3984 Traction Motor 2 Status.....................................................3985 Occupancy Sensor............................................................3985 Brake System Sensors........................................................3985 Pump Status.................................................................3986 Hydraulic Control Inputs....................................................3986 E-Hydraulic Valves..........................................................3986 Hydraulic Sensors...........................................................3987 System Voltages.............................................................3988 Steering Position Sensors...................................................3988 tables..............................................................................3885 Table 1. Technician Menu Flowchart..............................................3897 Table 2. Soft Key Icons.........................................................3902 Table 3. Overlay Icons..........................................................3903 Table 4. Alert Screen Icons.....................................................3903 Table 5. Main Menu Title Screens................................................3906 Table 6. Operating Screen Icons.................................................3908 Table 7. Password Screen Icons..................................................3909 Table 8. Activity Log Submenus and Icons........................................3909 Table 9. Calibration Submenus and Icons.........................................3911 Table 10. Display Submenus and Icons............................................3914 Table 11. Status Submenus and Icons.............................................3916 Table 12. Truck Setup Submenu Icons.............................................3919 Table 13. Diagnostic Submenu Icons..............................................3931 Table 14. BSOC in Relation to BDI...............................................3941 Table 15. Add Password..........................................................3946 Table 16. Change or Remove Password.............................................3948 Table 17. Access Operator Checklist Log Screens.................................3951 Table 18. Access Password Log Screens...........................................3953 Table 19. Access Impact Events Log Screens......................................3955 Table 20. Accessing the Set Date and Time Format Screen.........................3961 Table 21. Set Daylight Saving Time Menu.........................................3963 Table 22. Battery Setup Factory Defaults........................................3971 Hyster-S50XN-1688883-8000SRM1374-(07-2009)-US-EN........................................3991 toc.................................................................................3991 Capacities and Specifications...................................................3991 Safety Precautions Maintenance and Repair.......................................3992 Counterweights..................................................................3995 Hydraulic System................................................................3995 Steering System.................................................................3996 Specifications..............................................................3996 Turning Radius..............................................................3996 Wheels and Tires................................................................3997 Battery Specifications..........................................................3998 Capacities......................................................................3998 Tilt Angles.....................................................................3999 Drift Rates (Maximum) for Tilt Cylinders........................................3999 Mast Speeds.....................................................................4000 Torque Specifications...........................................................4006 Frame.......................................................................4006 Drive Axle..................................................................4006 Differential and Speed Reducer..............................................4006 Brake System................................................................4006 Steering Axle...............................................................4007 Masts.......................................................................4007 Tilt Cylinders..............................................................4007 Hydraulic Pump and Motor....................................................4007 Hydraulic Tank..............................................................4008 Hydraulic Control Valves....................................................4008 Manual Valve............................................................4008 Manual Handles and Levers...............................................4008 Manual Valve Covers.....................................................4008 E-Hydraulic Valve.......................................................4008 Electrical System...........................................................4009 Adhesives and Sealants..........................................................4009 tables..............................................................................3991 Table 1. Manual Hydraulic Control Valve.........................................3995 Table 2. E-Hydraulic Control Valve..............................................3996 Table 3. Lift/Lower Speed, Standard Performance, 36 Volts.......................4000 Table 4. Lift/Lower Speed, Standard Performance, 48 Volts.......................4001 Table 5. Lift/Lower Speed Enhanced Performance, 48 Volts........................4003 Table 6. Lift/Lower Speed, Enhanced Performance, 80 Volts.......................4004 Hyster-S50XN-Industrial-Battery-899648-2240SRM0001-(02-2008)-US-EN......................4013 toc.................................................................................4013 Industrial Battery..............................................................4013 Safety Precautions Maintenance and Repair.......................................4014 General.........................................................................4017 Lead-Acid Batteries.............................................................4017 Specific Gravity................................................................4018 Chemical Reaction in a Cell.....................................................4018 Electrical Terms................................................................4019 Battery Selection...............................................................4020 Battery Voltage.................................................................4021 Battery as a Counterweight......................................................4021 Battery Ratings.................................................................4022 Kilowatt-Hours..............................................................4022 Battery Maintenance.............................................................4022 Safety Procedures...........................................................4022 Maintenance Records.........................................................4023 New Battery.................................................................4023 Cleaning Battery............................................................4023 Adding Water to Battery.....................................................4025 Hydrometer..................................................................4026 Battery Temperature.........................................................4026 Charging Battery............................................................4027 Types of Battery Charges................................................4028 Methods of Charging.....................................................4029 Troubleshooting Charger.................................................4030 Knowing When Battery Is Fully Charged...................................4030 Where to Charge Batteries...................................................4030 Equipment Needed........................................................4030 Battery Connectors..........................................................4031 Battery Care................................................................4031 tables..............................................................................4013 Table 1. Battery Capacity Terms.................................................4022 Hyster-S50XN-Parts-Manual-(07-2011).....................................................4035 1688880-2200SRM1369-(07-2011)-US-EN.................................................4035 toc.............................................................................4035 Electrical System...........................................................4035 Safety Precautions Maintenance and Repair...................................4036 General.....................................................................4043 Discharging the Capacitors..............................................4044 Display Panel and Key or Keyless Switch Replacement.........................4045 Display Panel, Replace..................................................4045 Remove..............................................................4045 Install.............................................................4046 Electronic and Manual Hydraulic Controls....................................4048 General.................................................................4048 Manual Hydraulic Controls...............................................4048 Upper Front Cover...................................................4048 Direction Control Switch............................................4050 Remove..........................................................4050 Install.........................................................4050 Clamp Button........................................................4054 Remove..........................................................4054 Install.........................................................4054 Emergency Disconnect Switch.........................................4054 Remove..........................................................4054 Install.........................................................4055 E-Hydraulic Controls - Test.............................................4056 Mini-Levers.........................................................4056 Full Stroke Test....................................................4056 Function Returns to Neutral Test....................................4056 Push Button Switch..................................................4056 E-Hydraulic Controls....................................................4056 Mini-levers, Remove and Install.....................................4057 Armrest Assembly....................................................4058 Remove..........................................................4058 Install.........................................................4059 Horn Button.........................................................4060 Remove..........................................................4060 Install.........................................................4060 Direction Control Switch............................................4061 Remove..........................................................4061 Install.........................................................4061 Emergency Disconnect Switch.........................................4062 Remove..........................................................4062 Install.........................................................4062 Momentary Switches and Function Selection Button....................4063 Remove..........................................................4063 Install.........................................................4064 Sensors and Switches........................................................4065 General.................................................................4065 Steering Axle Sensor....................................................4065 Remove..............................................................4065 Install.............................................................4067 Hydraulic Motor Speed Sensor............................................4068 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)......................4068 Remove..........................................................4068 Install.........................................................4068 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)......................4071 Remove..........................................................4071 Install.........................................................4071 Lift Truck Models E1.6-2.0XN (E30-40XN) (A269)......................4073 Remove..........................................................4073 Install.........................................................4073 Hydraulic Motor Temperature Sensor......................................4073 Hydraulic Tank Level Sensor.............................................4074 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)......................4074 Remove..........................................................4074 Install.........................................................4074 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E....4075 Remove..........................................................4075 Install.........................................................4075 Hydraulic Filter Sensor.................................................4076 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)......................4076 Remove..........................................................4076 Install.........................................................4076 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E....4076 Remove..........................................................4076 Install.........................................................4077 Hydraulic Oil Temperature Sensor........................................4078 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)......................4078 Remove..........................................................4078 Install.........................................................4078 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268)......................4078 Remove..........................................................4078 Install.........................................................4078 Traction Speed Sensor...................................................4079 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)......................4079 Remove..........................................................4079 Install.........................................................4080 E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E30-40XN) (A269).......4080 Remove..........................................................4080 Install.........................................................4080 Traction Motor Temperature Sensor.......................................4082 Tilt Position Sensor E2.2-3.5XN (E45-70XN) (A268) and J2.2-3.5XN........4082 Remove..............................................................4082 Install.............................................................4083 Tilt Position Sensor E1.6-2.0XN (E30-40XN) (A269).......................4084 Remove..............................................................4084 Install.............................................................4084 Low Level Brake Fluid Switch............................................4084 Remove..............................................................4084 Install.............................................................4085 Service Brake Pressure Sensor...........................................4087 Remove..............................................................4087 Install.............................................................4087 Accelerator Pedal Position Sensor.......................................4087 Remove..............................................................4087 Install.............................................................4087 Seat Sensor (Operator Presence System)..................................4089 Non-Suspension Seat.................................................4089 Remove..........................................................4089 Install.........................................................4090 Full Suspension and Swivel Seats....................................4090 Remove..........................................................4090 Install.........................................................4090 Steering Direction Sensor...............................................4091 Remove..............................................................4091 Install.............................................................4091 Load Weight Sensor......................................................4092 Remove..............................................................4092 Install.............................................................4093 Battery Gate Switch.....................................................4093 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E....4094 Remove..........................................................4094 Install.........................................................4094 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)......................4096 Remove..........................................................4096 Install.........................................................4096 Horn Switch.............................................................4097 Fixed Steering Column...............................................4097 Remove..........................................................4097 Install.........................................................4097 Telescopic Steering Column..........................................4098 Remove..........................................................4098 Install.........................................................4099 Impact Sensor...........................................................4099 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)......................4099 Remove..........................................................4099 Install.........................................................4100 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E....4101 Remove..........................................................4101 Install.........................................................4102 Rear and Hood Horn Button Switches......................................4102 Rear Horn Button Switch.............................................4102 Remove..........................................................4102 Install.........................................................4103 Hood Horn Button Switch.............................................4103 Remove..........................................................4103 Install.........................................................4103 Motor Controllers Replacement...............................................4105 General.................................................................4105 Lift Truck Models E2.2-3.5XN (E45-70XN) (A268) and E1.6-2.0XN (E........4109 Traction Motor and Hydraulic Pump and Motor Controllers.............4109 Remove..........................................................4109 Install.........................................................4109 Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)..........................4112 Hydraulic Pump and Motor Controller.................................4112 Remove..........................................................4112 Install.........................................................4112 Traction Motor Controllers..........................................4114 Remove..........................................................4114 Install.........................................................4114 Line Contactor..........................................................4117 Remove..............................................................4117 Install.............................................................4117 Fans....................................................................4119 Remove..............................................................4119 Install.............................................................4120 Vehicle System Manager......................................................4121 General.................................................................4121 Remove..................................................................4121 Install.................................................................4121 Programming a New VSM and/or Display Panel..............................4123 General.............................................................4123 PC Service Tool Software................................................4123 Fuses and Relays............................................................4124 Fuses...................................................................4124 Relays..................................................................4127 Backup Alarm................................................................4130 Battery Connection..........................................................4132 Inspect.................................................................4132 Replacing Cables........................................................4132 Cab Heater..................................................................4134 Lights......................................................................4134 General.................................................................4134 Work Lights (Front and Rear)............................................4137 Halogen Bulb Lights.................................................4137 Remove..........................................................4137 Install.........................................................4137 LED Lights..........................................................4138 Remove..........................................................4138 Install.........................................................4138 Strobe Light............................................................4138 Remove..............................................................4138 Install.............................................................4138 LED Tail, Backup, and Brake Lights......................................4139 Remove..............................................................4139 Install.............................................................4139 Front Marker/Turn Signal Lights.........................................4140 Remove..............................................................4140 Install.............................................................4140 Dome Light..............................................................4140 Remove..............................................................4140 Install.............................................................4140 Converter...............................................................4141 Remove..............................................................4141 Install.............................................................4141 1701941-8000SRM1384-(07-2011)-US-EN.................................................4147 toc.............................................................................4147 Diagrams....................................................................4147 Safety Precautions Maintenance and Repair...................................4148
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