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Hyster D098 Service Manual – PDF DOWNLOAD
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Description
Hyster D098 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster D098 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 HOW TO 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 whenmaking 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 D098 Service Manual – PDF DOWNLOAD
897108-1600SRM0326-(03-2005)-US-EN...................................................... 1 toc................................................................................. 1 Steering Axle................................................................... 1 Safety Precautions Maintenance and Repair....................................... 2 General......................................................................... 5 Description..................................................................... 5 Steering Axle Assembly Repair................................................... 10 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70............ 10 Remove.................................................................. 10 Install................................................................. 10 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0............ 11 Remove.................................................................. 11 Install................................................................. 11 Wheels and Hubs Repair (All Units).............................................. 12 Remove and Disassemble...................................................... 12 Clean....................................................................... 12 Inspect..................................................................... 12 Assemble and Install........................................................ 12 Spindles and Bearings Repair (All Units)........................................ 14 Remove...................................................................... 14 Clean....................................................................... 14 Assemble and Install........................................................ 14 Tie Rods Repair (All Units)..................................................... 15 Remove...................................................................... 15 Clean....................................................................... 15 Install..................................................................... 15 Steering Cylinder Repair........................................................ 18 Remove and Disassemble...................................................... 18 Clean and Inspect........................................................... 18 Assemble and Install........................................................ 18 Troubleshooting................................................................. 19 897120-1800SRM0338-(07-2005)-US-EN...................................................... 23 toc................................................................................. 23 Brake System.................................................................... 23 Safety Precautions Maintenance and Repair....................................... 24 General......................................................................... 27 Description and Operation....................................................... 27 Brake Booster and Master Cylinder........................................... 27 Master Cylinder............................................................. 27 Service Brake Assembly...................................................... 27 Parking Brake............................................................... 30 Seat Brake.................................................................. 31 Brake Shoe Assemblies Repair.................................................... 32 Remove and Disassemble...................................................... 32 Clean and Inspect........................................................... 32 Assemble and Install........................................................ 34 Master Cylinder Repair.......................................................... 38 Master Cylinder S3.50-5.50XL (S70-120XL) and H3.50-5.00XL (H70-1............ 38 Remove.................................................................. 38 Disassemble............................................................. 38 Assemble................................................................ 38 Install................................................................. 38 Master Cylinder E3.50-5.50XL (E70-120XL, E70-120XL 3 ) [A839] an............ 39 Remove and Disassemble.................................................. 39 Clean and Inspect....................................................... 40 Assemble and Install.................................................... 41 Brake Booster Repair............................................................ 41 Remove...................................................................... 41 Disassemble................................................................. 41 Clean and Inspect........................................................... 41 Assemble.................................................................... 42 Install..................................................................... 43 Brake System Air Removal........................................................ 43 Brake Pedal Adjustment.......................................................... 43 Brake Pedal H3.50-5.00XL (H70-110XL) With Manual Transmission an............ 43 Brake Shoes Adjustment.......................................................... 45 Parking Brake Adjustment........................................................ 45 Parking Brake Adjustment S3.50-5.50XL (S70-120XL) and H3.50-5.00............ 45 Parking Brake Lever and Switch Adjustment E3.50-5.50XL (E70-120X............ 46 Seat Brake Assembly............................................................. 46 Remove...................................................................... 46 Clean and Inspect........................................................... 48 Install..................................................................... 48 Adjustments................................................................. 48 Solenoid Adjustment..................................................... 48 Cable Adjustment........................................................ 50 Brake Booster Relief Valve Check................................................ 50 Troubleshooting................................................................. 50 897345-1400SRM0413-(03-2005)-US-EN...................................................... 55 toc................................................................................. 55 Drive Axle, Speed Reducer, and Differential..................................... 55 Safety Precautions Maintenance and Repair....................................... 56 General......................................................................... 59 Description..................................................................... 59 Drive Axle, Speed Reducer, and Differential Repair.............................. 60 Remove...................................................................... 60 General................................................................. 60 Traction Motor, Speed Reducer, and Differential......................... 61 Motor, Speed Reducer, and Differential, Remove...................... 62 Disassemble................................................................. 65 Speed Reducer........................................................... 65 Differential............................................................ 65 Clean....................................................................... 65 Inspect..................................................................... 66 Assemble.................................................................... 66 Speed Reducer........................................................... 66 Input Gear, Install................................................. 66 New Pinion, Install................................................. 66 Differential............................................................ 68 Drive Axle Housing.......................................................... 72 Remove.................................................................. 72 Clean................................................................... 72 Inspect................................................................. 73 Assemble................................................................ 74 Troubleshooting................................................................. 75 tables.............................................................................. 55 Table 1. Pinion Assembly Shims Adjustment....................................... 68 Table 2. Ring and Pinion Tooth Contact Adjustment............................... 70 897639-1900SRM0559-(03-2005)-US-EN...................................................... 79 toc................................................................................. 79 Hydraulic System................................................................ 79 Safety Precautions Maintenance and Repair....................................... 80 General......................................................................... 83 Description..................................................................... 83 Hydraulic System............................................................ 83 Operation....................................................................... 88 Hydraulic System............................................................ 88 Hydraulic Gear Pump......................................................... 88 Rotator Actuator Valve...................................................... 91 Steering Pump............................................................... 91 Hydraulic Tank Repair...........................................................101 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), E1.50-2.00XM ............101 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.00-3.20XM (J4............102 E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) Tank, Remove an............103 Inspect.....................................................................104 Small Leaks, Repair.........................................................104 Large Leaks, Repair.........................................................104 Clean.......................................................................104 Steam Method............................................................104 Chemical Solution Method................................................105 Additional Methods for Tank Repair..........................................105 E1.50-3.20XM (E25-65XM, E25-65XM 2 ), (D114, F108), E1.50-2.00XM............105 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.00-3.20XM (J4............106 Filter Replacement..............................................................106 All Lift Trucks Except E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)............106 Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D09............107 Hydraulic Pump Repair...........................................................108 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), N30XMH, and N............108 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216), J2.00-3.20XM (J40-6............109 Pump Seal, Replace and Pump Assemble........................................110 Assemble Pump on Motor......................................................110 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), N30XMH, and N............110 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216), J2.00-3.20XM (J40-6............113 E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) Hydraulic Pump,............114 E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) Hydraulic Pump,............115 E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) Hydraulic Pump,............115 E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) Hydraulic Pump,............115 E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) Hydraulic Pump,............115 E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098) Hydraulic Pump ............118 Main Control Valve Repair.......................................................118 Steering Pump Repair............................................................119 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), N30XMH, and N............119 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216), J2.00-3.20XM (J40-6............120 Pump, Assemble and Install..................................................122 Rotary Actuator Valve Repair....................................................123 Disassemble, Clean, and Inspect.............................................123 Assemble....................................................................123 Steering Control Unit Repair....................................................124 Remove......................................................................124 Install.....................................................................124 Steering Cylinder Repair........................................................129 Main Control Valve Check and Adjust.............................................129 Steering Relief Valve Check and Adjust..........................................129 Specifications..................................................................130 Relief Valve Pressures*.....................................................130 Hydraulic Tank Capacity (dipstick full mark)................................131 Hydraulic Pump Capacities - All Models Except E3.50-5.50XL, E4.5............131 Hydraulic Pump Capacities - Models E3.50-5.50XL, E4.50XLS (E70-1............131 Troubleshooting.................................................................131 Steering....................................................................131 Steering Housing and Steering Control Unit..................................132 Hydraulic System............................................................133 899648-2240SRM0001-(11-2003)-US-EN......................................................139 toc.................................................................................139 Industrial Battery..............................................................139 Safety Precautions Maintenance and Repair.......................................140 General.........................................................................143 Lead-Acid Batteries.............................................................143 Specific Gravity................................................................144 Chemical Reaction in a Cell.....................................................144 Electrical Terms................................................................145 Battery Selection...............................................................146 Battery Voltage.................................................................147 Battery as a Counterweight......................................................147 Battery Ratings.................................................................147 Kilowatt-Hours..............................................................147 Battery Maintenance.............................................................148 Safety Procedures...........................................................148 Maintenance Records.........................................................148 New Battery.................................................................148 Cleaning Battery............................................................149 Adding Water to Battery.....................................................150 Hydrometer..................................................................151 Battery Temperature.........................................................151 Charging Battery............................................................152 Types of Battery Charges................................................153 Methods of Charging.....................................................154 Troubleshooting Charger.................................................155 Knowing When Battery Is Fully Charged...................................155 Where to Charge Batteries...................................................155 Equipment Needed........................................................155 Battery Connectors..........................................................156 Battery Care................................................................156 tables..............................................................................139 Table 1. Battery Capacity Terms.................................................147 899782-2000SRM0077-(03-2005)-US-EN......................................................161 toc.................................................................................161 Main Control Valve..............................................................161 Safety Precautions Maintenance and Repair.......................................162 General.........................................................................165 Description.....................................................................165 Operation.......................................................................165 Lift Section................................................................165 Tilt Section................................................................169 Tilt Backward...........................................................169 Tilt Forward............................................................169 Relief Valve............................................................169 Solenoid Valve for Auxiliary Function.......................................169 Main Control Valve Repair.......................................................172 Remove and Disassemble......................................................172 Clean and Inspect...........................................................173 Assemble....................................................................173 Install.....................................................................173 Solenoid Valve for Auxiliary Function Repair....................................173 Remove and Disassemble......................................................173 Assemble and Install........................................................175 Troubleshooting.............................................................176 Pressure Relief Valve Check and Adjustment......................................176 Primary Relief Valve........................................................176 Secondary Relief Valve......................................................177 Control Lever Arrangement and Adjustment........................................178 Specifications..................................................................180 Troubleshooting.................................................................180 910102-2100SRM0103-(03-2005)-US-EN......................................................185 toc.................................................................................185 Tilt Cylinders..................................................................185 Safety Precautions Maintenance and Repair.......................................186 General.........................................................................189 Description.....................................................................189 Tilt Cylinder Repair............................................................189 Remove......................................................................189 Disassemble.................................................................189 Clean.......................................................................189 Assemble....................................................................190 Tilt Cylinders With O-Ring or Single-Lip Seals..........................190 Tilt Cylinders for XM and XMS Models....................................191 Tilt Cylinders for XL, XLS, and XL 3 Models.............................192 Tilt Cylinders for H700-800A and Early Model H700-920B..................194 Install.....................................................................195 Tilt Cylinders Using Chevron Packing....................................195 Install.............................................................196 Tilt Cylinder Leak Check........................................................198 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.............................200 Torque Specifications...........................................................200 Piston Rod Nut..............................................................200 Retainer....................................................................201 Troubleshooting.................................................................203 tables..............................................................................185 Table 1. Movement Rates (Maximum) for Tilt Cylinders............................199 910442-8000SRM0231-(12-2004)-US-EN......................................................207 toc.................................................................................207 Metric and Inch (SAE) Fasteners.................................................207 Safety Precautions Maintenance and Repair.......................................208 General.........................................................................211 Threaded Fasteners..........................................................211 Nomenclature, Threads.......................................................211 Strength Identification.....................................................212 Cotter (Split) Pins.........................................................212 Fastener Torque Tables......................................................217 Conversion Table............................................................219 tables..............................................................................207 Table 1. Bolts and Screws.......................................................213 Table 2. Studs and Nuts.........................................................214 Table 3. Torque Nuts............................................................215 Table 4. Torque Nuts With Nylon Insert..........................................216 Table 5. Torque Values for Metric Fasteners*....................................217 Table 6. Torque Values for Inch Fasteners*......................................218 Table 7. Conversion Table for Metric and English Units..........................219 Table 8. Cotter Pin Dimensional Data............................................220 Table 9. Cotter Pin Dimensional Data............................................221 Table 10. Cotter Pin Dimensional Data...........................................222 Table 11. Cotter Pin Dimensional Data...........................................224 1459370-1600SRM0720-(07-2005)-US-EN.....................................................229 toc.................................................................................229 Steering Housing and Control Unit...............................................229 Safety Precautions Maintenance and Repair.......................................230 General.........................................................................233 Description.....................................................................233 Operation.......................................................................234 Steering Wheel and Column Assembly Repair.......................................235 Assembly Components, Remove.................................................235 Steering Control Unit, Disassemble..........................................240 Steering Control Unit, Clean................................................240 Steering Control Unit, Assemble.............................................240 Assembly Components, Install................................................242 System Air Removal..............................................................244 Troubleshooting.................................................................244 1466163-4000SRM0736-(03-2005)-US-EN.....................................................249 toc.................................................................................249 Masts...........................................................................249 Safety Precautions Maintenance and Repair.......................................250 General.........................................................................253 Description and Operation.......................................................253 Carriages...................................................................253 Two-Stage Mast With Limited Free-Lift.......................................253 Two-Stage Mast With Full Free-Lift..........................................254 Three-Stage Mast With Full Free-Lift........................................255 Safety Procedures When Working Near Mast........................................257 Fork Replacement................................................................259 Remove......................................................................260 Install.....................................................................260 Carriage Repair.................................................................261 Remove......................................................................261 Sideshift Carriage Repair.......................................................262 Remove......................................................................262 Disassemble.................................................................263 Assemble....................................................................263 Install.....................................................................263 Two-Stage Mast With Limited Free-Lift Repair....................................264 Remove, H3.50-5.50XM (H70-120XM) Model Lift Trucks..........................264 Remove, S3.50-5.50XM (S70-120XM), E3.50-5.50XL 3 (E70-120XL 3 ) ............264 Disassemble.................................................................268 Clean and Inspect...........................................................268 Assemble....................................................................269 Install, H3.50-5.50XM (H70-120XM) Lift Truck Models.........................270 Install, S3.50-5.50XM (S70-120XM), E3.50-5.50XL 3 (E70-120XL 3 )............272 Two-Stage Mast With Full Free-Lift Repair.......................................274 Remove......................................................................274 Disassemble.................................................................274 Clean and Inspect...........................................................274 Assemble....................................................................276 Install.....................................................................276 Three-Stage Mast With Full Free-Lift Repair.....................................278 Remove......................................................................278 Disassemble.................................................................278 Clean and Inspect...........................................................282 Assemble....................................................................282 Install.....................................................................282 Mast Operation Check............................................................287 Lift and Tilt System Leak Check.................................................287 Lift System.................................................................287 Tilt System.................................................................288 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.........................289 Lift Chain Adjustments..........................................................291 Mast Adjustments................................................................293 Carriage Adjustment.............................................................295 Troubleshooting.................................................................295 tables..............................................................................249 Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (................289 Table 2. Hook type Carriage Chain Adjustment....................................291 Table 3. Pin-Type Carriage Chain Adjustment.....................................292 1466169-4000SRM0741-(03-2005)-US-EN.....................................................301 toc.................................................................................301 Lift Cylinders..................................................................301 Safety Precautions Maintenance and Repair.......................................302 Safety Procedures When Working Near Mast........................................305 General.........................................................................307 Description.....................................................................307 Lowering Control Valve (Velocity Fuse)......................................307 Lift Cylinder Repair............................................................310 Remove......................................................................310 Disassemble.................................................................311 Assemble....................................................................311 Install.....................................................................312 Lift System Leak Check..........................................................312 Troubleshooting.................................................................313 1534733-1600SRM1054-(07-2005)-US-EN.....................................................317 toc.................................................................................317 Steering System for AC Electric Lift Trucks.....................................317 Safety Precautions Maintenance and Repair.......................................318 General.........................................................................321 Description.....................................................................321 Steering Wheel and Column Assembly Repair.......................................323 General.....................................................................323 Assembly Components, Remove.................................................323 Assembly Components, Install................................................326 Power Steering Motor and Pump...................................................327 Description.................................................................327 Remove......................................................................327 Disassemble.................................................................330 Install.....................................................................330 Power Steering Pump, Repair.................................................330 Seal, Replace...........................................................330 Steering System Air Removal.....................................................332 Steering Pressure Check.........................................................332 Steering Motor Circuits Check...................................................333 Troubleshooting.................................................................334 1534734-2200SRM1055-(07-2005)-US-EN.....................................................339 toc.................................................................................339 Electrical System (Trucks With AC Controllers)..................................339 Safety Precautions Maintenance and Repair.......................................340 General.........................................................................343 Description.....................................................................344 Features of the Display Panels..............................................344 Other Control Components....................................................345 Display Panel and Key Switch Replacement........................................345 Display Panel, Replace......................................................345 Key Switch, Replace.........................................................347 Controller Replacement..........................................................347 Traction and Pump Motor Controller Replacement..............................347 Master Controller Replacement ..............................................353 Master Controller Removal J2.00-3.20XM (J40-60Z) (A416).................353 Master Controller Install J2.00-3.20XM (J40-60Z) (A416).................354 Master Controller Removal E1.50-2.00XM (E25-35Z, E40ZS) (E114), ........354 Master Controller Install E1.50-2.00XM (E25-35Z, E40ZS) (E114), ........354 Master Controller Removal E3.50-5.50XL E4.50XLS (E70-120Z,E100ZS........354 Master Controller Install E3.50-5.50XL E4.50XLS (E70-120Z,E100ZS........355 Control Components Replacement..................................................356 General.....................................................................356 Start Switch, Replace.......................................................356 Brake Light Switch, Replace.................................................357 Seat Switch, Replace........................................................358 Parking Brake Switch, Replace...............................................358 MONOTROL Pedal Direction Switches, Replace..................................360 Steering Column Direction Control Switches, Replace.........................363 Brake Fluid Switch, Replace.................................................363 Brush Wear and Over Temperature Sensors (DC Pump Motor Only)................364 Rocker Switches for Lights, Replace.........................................364 Accelerator Position Sensor, Replace........................................364 On-Demand Steering Sensor, Replace..........................................365 Lights, Converter, Relay, and Reverse Alarm.................................366 Brake, Tail, and Reverse Light Assembly, Replace........................366 Incandescent Assembly...............................................366 LED Assembly - Remove...............................................368 LED Assembly - Install..............................................370 Strobe Light Assembly, Replace..........................................370 Del-City Crimp-Solder-Shrink Splice.....................................371 Front, Rear Driving Light, or Spot Light Assemblies, Replace............372 Converter, Replace......................................................373 Reverse Relay, Replace..................................................374 Lift Truck Models J2.00-3.20XM (J40-65Z) (A416), V30ZMD (D210), ....374 Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D09....374 Backup Alarm, Replace...................................................374 Horn and Horn Button, Replace...............................................375 Horn Switch and Cover, Replace..........................................375 Hydraulic Pump Switches.....................................................376 Fan Power Supply, Replace...................................................376 Control and Power Fuse Check....................................................377 Fuse Locations..............................................................377 Brake Light Switch Adjustment...................................................382 Seat Switch Check...............................................................383 Seat Brake Adjustment...........................................................383 Parking Brake Switch Adjustment.................................................383 Direction Switches Check........................................................384 MONOTROL Pedal..............................................................384 Steering Column.............................................................385 MONOTROL Pedal or Accelerator Pedal Adjustment..................................385 Accelerator Position Sensor Adjustment and Start Switch Adjustme................386 Acceleration Position Sensor, Adjust........................................386 Start Switch, Adjust........................................................387 tables..............................................................................339 Table 1. Wire Splice Size.......................................................371 1534735-2200SRM1056-(07-2005)-US-EN.....................................................391 toc.................................................................................391 AC Motor Controllers/Display Panel..............................................391 Safety Precautions Maintenance and Repair.......................................392 Description.....................................................................395 General.....................................................................395 AC Motors...............................................................395 Motor Controllers.......................................................395 Master Controller.......................................................395 Dash Display............................................................395 Controller Area Network Bus (CANBus)....................................395 Master Controller Checks and Adjustments........................................396 Function Settings...............................................................396 General.....................................................................396 Function Numbers............................................................396 Function Descriptions...........................................................399 General.....................................................................399 Function Number 1 BATTERY VOLTAGE.......................................399 Function Number 2 EXTENDED SHIFT........................................399 Function Number 3 ACCELERATION 1........................................399 Function Number 4 ACCELERATION 2........................................399 Function Number 5 TOP SPEED LIMIT.......................................399 Function Number 6 REGEN BRAKING.........................................400 Function Number 7 AUTO DECELERATION.....................................400 Function Number 8 BDI ADJUSTMENT........................................400 Function Number 9 LIFT INTERRUPT........................................400 Function Number 10 POWER STEERING TIME DELAY............................400 Function Number 11 SERVICE REMINDER.....................................400 Function Number 12 CUSTOM...............................................400 Function Number 13 PUMP SPEED 1.........................................401 Function Number 14 PUMP SPEED 2.........................................401 Function Number 15 PUMP SPEED 3.........................................401 Function Number 16 PUMP ACCELERATION....................................401 Troubleshooting.................................................................401 General.....................................................................401 Controller Status Light Emitting Diodes (LEDs)..............................402 AC Master Controller....................................................402 AC Motor Controllers....................................................402 Status Codes................................................................408 AC Motor Controllers Status Code Charts.........................................409 AC Transistor Motor Controller Replacement......................................424 General.....................................................................424 General Maintenance Instructions............................................430 Special Precautions.....................................................430 Fuses.......................................................................431 Fan Test....................................................................431 Contactors..................................................................431 Repair..................................................................431 Thermal Sensors.............................................................435 Motor Controller, Replace...................................................435 Display Panel...................................................................436 General.....................................................................436 Premium Display Panel...................................................436 Standard Display Panel..................................................436 Display Functions and Features..................................................437 Key-On Initialization.......................................................437 Standard Display............................................................438 Premium Display.............................................................438 Lift Truck Inspection Function..............................................439 Access to Service Functions.................................................439 Service Functions...........................................................439 Performance Modes...........................................................440 Battery Discharge Indication (BDI)..........................................440 Hourmeter...................................................................441 Dash Display Service Menu Navigation............................................441 General.....................................................................441 Moving Through Menu Selections..............................................442 Editing and Adding Information..............................................442 tables..............................................................................391 Table 1. Factory Parameter Table - J2.00-3.20XM (J40-65Z) (A416)................396 Table 2. Factory Setting Table - V30ZMD (D210), E2.00-3.20XM (E4................397 Table 3. Factory Setting Table - E1.50-2.00XM (E25-35Z, E40ZS) (................397 Table 4. Factory Parameter Table - E3.50-5.50XL, E4.50XLS (E70-1................398 Table 5. List of Status Codes...................................................408 Table 6. 42-Pin Connections/Descriptions for Master Controller..................432 Table 7. Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo................434 Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen................434 1534737-2200SRM1058-(07-2005)-US-EN.....................................................445 toc.................................................................................445 Troubleshooting and Adjustments Using the AC Controls Program (E................445 Safety Precautions Maintenance and Repair.......................................446 General.........................................................................449 Computer Requirements.......................................................449 Software, Install...........................................................449 Language Selection..........................................................449 Demo Mode...................................................................450 Connect PC to Lift Truck....................................................452 Starting AC Controls Program................................................453 Lift Truck Control Setup........................................................458 Change Lift Truck Serial Number or Hourmeter................................458 Setting Factory Default Values or Changing Lift Truck Parameters............460 Create New Custom Lift Truck Configuration..................................465 Lift Truck Configuration Properties.........................................469 Import New Lift Truck Configuration From Disk...............................473 Delete Custom Lift Truck Configuration or Password File.....................473 Dash Display....................................................................477 Custom Display Languages....................................................477 Download Display Language...................................................480 Clear Operator Log..........................................................480 Clear Status Log............................................................480 Password Functions..............................................................484 Enable/Disable Password and Lift Truck Inspection Functions.................484 Truck Inspection Checklist..............................................484 Password................................................................484 Password Properties.........................................................484 Create New Password File....................................................490 Download Passwords..........................................................490 Upload Passwords............................................................490 Reports Menu....................................................................496 Passwords...................................................................496 Status Codes................................................................499 Operators...................................................................502 Current Settings............................................................505 Troubleshooting.................................................................508 Diagnostics.................................................................508 Help Menu.......................................................................511 General.....................................................................511 Contents....................................................................511 Technical Support...........................................................513 About Electric Truck AC Controls Program....................................515 1556364-0620SRM1098-(07-2005)-US-EN.....................................................521 toc.................................................................................521 AC Motor Repair.................................................................521 Safety Precautions Maintenance and Repair.......................................522 General.........................................................................525 AC Motor Repair.................................................................525 Disassemble.................................................................525 Assemble....................................................................529 Troubleshooting.................................................................531 1596602-0100SRM1200-(07-2005)-US-EN.....................................................535 toc.................................................................................535 Frame...........................................................................535 Safety Precautions Maintenance and Repair.......................................536 General.........................................................................539 Description.....................................................................539 Overhead Guard Repair...........................................................542 Remove......................................................................542 Install.....................................................................542 Battery and Operator Restraint, Hood and Seat Brake Repair......................543 Battery Restraint and Hood Repair...........................................543 Operator Restraint Repair...................................................545 Seat Brake Repair...........................................................546 Counterweight Repair............................................................546 Remove......................................................................546 Install.....................................................................547 Traction Motor Repair...........................................................547 Remove......................................................................547 Install.....................................................................549 Hydraulic Tank Repair...........................................................549 Inspect.....................................................................549 Small Leaks, Repair.........................................................550 Large Leaks, Repair.........................................................550 Clean.......................................................................550 Steam Method............................................................550 Chemical Solution Method................................................550 Additional Preparations For Repair..........................................551 Safety Label Replacement........................................................551 Battery Specifications..........................................................553 tables..............................................................................535 Table 1. Torque Values..........................................................542 Table 2. Weight of Counterweights...............................................546 Table 3. Battery Specifications*................................................553 1596603-8000SRM1201-(07-2005)-US-EN.....................................................557 toc.................................................................................557 Periodic Maintenance............................................................557 Safety Precautions Maintenance and Repair.......................................558 General.........................................................................561 How to Move Disabled Lift Truck.............................................561 How to Tow Lift Truck...................................................561 How to Put Lift Trucks on Blocks............................................562 How to Raise Drive Tires................................................562 How to Raise Steering Tires.............................................563 Maintenance Schedule............................................................564 Maintenance Procedures Every 8 Hours or Daily...................................567 General.....................................................................567 How to Make Checks With Key Switch OFF......................................567 Tires and Wheels........................................................567 Forks...................................................................568 Adjust..............................................................568 Remove..............................................................568 Install.............................................................568 Inspection of Forks, Mast, Mast Pivots, and Lift Chains.................569 Safety Labels...........................................................570 Steering Column Latch...................................................570 Operator Restraint System...............................................570 Battery Restraint System................................................571 Battery.................................................................572 Hydraulic System........................................................572 How to Make Checks With Key Switch ON.......................................573 Gauges and Horn.........................................................573 Steering System.........................................................573 Service Brakes..........................................................573 Parking Brake...........................................................573 Seat Brake..............................................................573 Control Levers and Pedals...............................................573 Lift System Operation...................................................574 Maintenance Procedures Every 500 Hours or 3 Months..............................574 Wheel Nuts..................................................................574 Mast........................................................................574 Sideshift Carriage..........................................................575 Brake Fluid.................................................................575 Other Lubrication...........................................................575 Maintenance Procedures Every 1000 Hours or 6 Months.............................575 Differential and Speed Reducer..............................................575 Lift Chains.................................................................576 Wear Check..............................................................576 Lubrication.............................................................576 Forks.......................................................................577 Parking Brake...............................................................577 Brake Linkage Shafts........................................................577 Steering Spindles and Tie Rod Ends..........................................578 Seat Rails..................................................................578 Seat Plate Hinges...........................................................578 Electrical Inspection.......................................................578 Contactors..............................................................578 Maintenance Procedures Every 2000 Hours or Yearly...............................580 Brake Fluid.................................................................580 Hydraulic System............................................................581 Hydraulic Tank Breather.................................................581 Change Hydraulic Oil and Hydraulic Oil Filter...........................581 Differential and Speed Reducer..............................................583 Service Brakes..............................................................583 Wheel Bearings..............................................................583 Steer Wheels, Lubrication...............................................583 Drive Wheels, Lubrication...............................................583 Lift Chains.................................................................583 Battery Maintenance.............................................................584 How to Charge Battery.......................................................584 How to Change Battery.......................................................585 Safety Procedures When Working Near Mast........................................588 Lift and Tilt System Leak Check.................................................591 Check Lift Cylinders for Leaks..............................................591 Check Tilt Cylinders for Leaks..............................................591 Lift Chain Adjustments..........................................................592 Welding Repairs.................................................................593 Overhead Guard Changes..........................................................594 Wheels and Tires................................................................594 General.....................................................................594 Remove Wheels From Lift Truck...............................................594 Remove Tire From Wheel and Install Tire on Wheel............................594 Install Wheels..............................................................595 tables..............................................................................557 Table 1. Maintenance Schedule...................................................564 Table 2. Battery Specifications*................................................588 Table 3. Hook-Type Carriage Chain Adjustment....................................593 1596604-8000SRM1202-(07-2005)-US-EN.....................................................599 toc.................................................................................599 Capacities and Specifications...................................................599 Safety Precautions Maintenance and Repair.......................................600 Lift Truck Lifting Capacity.....................................................603 Counterweight Weights...........................................................603 Tire Sizes......................................................................603 Capacities......................................................................603 Hydraulic System................................................................604 Steering System.................................................................604 Specifications..............................................................604 Turning Radius..............................................................604 Mast Speeds.....................................................................605 Mast Creep Speeds...............................................................605 Battery Specifications..........................................................606 Traction Motor Speed............................................................606 Battery Current at Hoist Relief.................................................607 Torque Specifications...........................................................607 Brake System................................................................607 Differential................................................................607 Drive Axle..................................................................607 Frame.......................................................................607 Mast........................................................................607 Main Control Valve..........................................................608 Steering System.............................................................608 Tilt Cylinders..............................................................608 Hydraulic System............................................................608 Electrical System...........................................................608 1596605-8000SRM1203-(07-2005)-US-EN.....................................................611 toc.................................................................................611 Diagrams........................................................................611 Safety Precautions Maintenance and Repair.......................................612
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