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Hyster E098 Service Manual – PDF DOWNLOAD
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Description
Hyster E098 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster E098 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 E098 Service Manual – PDF DOWNLOAD
897108-1600SRM0326-(03-2007)-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........................................................ 15 Tie Rods Repair (All Units)..................................................... 16 Remove...................................................................... 16 Clean....................................................................... 16 Install..................................................................... 16 Steering Cylinder Repair........................................................ 19 Remove and Disassemble...................................................... 19 Clean and Inspect........................................................... 19 Assemble and Install........................................................ 19 Troubleshooting................................................................. 20 897120-1800SRM0338-(10-2006)-US-EN...................................................... 25 toc................................................................................. 25 Brake System.................................................................... 25 Safety Precautions Maintenance and Repair....................................... 26 General......................................................................... 29 Description and Operation....................................................... 29 Brake Booster and Master Cylinder........................................... 29 Master Cylinder............................................................. 29 Service Brake Assembly...................................................... 29 Parking Brake............................................................... 32 Seat Brake.................................................................. 33 Brake Shoe Assemblies Repair.................................................... 34 Remove and Disassemble...................................................... 34 Clean and Inspect........................................................... 36 Assemble and Install........................................................ 36 Master Cylinder Repair.......................................................... 41 Master Cylinder For Lift Truck Models S3.50-5.50XL (S70-120XL) (............ 41 Remove.................................................................. 41 Disassemble............................................................. 41 Assemble................................................................ 41 Install................................................................. 41 Master Cylinder For Lift Truck Models E3.50-5.50XL (E70-120XL, E............ 42 Remove and Disassemble.................................................. 42 Clean and Inspect....................................................... 43 Assemble and Install.................................................... 44 Brake Booster Repair............................................................ 44 Remove...................................................................... 44 Disassemble................................................................. 44 Clean and Inspect........................................................... 44 Assemble.................................................................... 45 Install..................................................................... 46 Brake System Air Removal........................................................ 46 Brake Pedal Adjustment.......................................................... 46 Brake Pedal for Lift Truck Models H3.50-5.00XL (H70-110XL) (F005............ 46 Brake Shoes Adjustment.......................................................... 48 Parking Brake Adjustment........................................................ 48 Parking Brake Adjustment, Lift Truck Models S3.50-5.50XL (S70-12............ 48 Parking Brake Lever and Switch Adjustment E3.50-5.50XL (E70-120X............ 49 Seat Brake Assembly............................................................. 50 Remove...................................................................... 50 Clean and Inspect........................................................... 50 Install..................................................................... 50 Adjustments................................................................. 52 Solenoid Adjustment..................................................... 52 Traction cutoff Switch Adjustment....................................... 52 Cable Adjustment........................................................ 53 Brake Booster Relief Valve Check................................................ 55 Troubleshooting................................................................. 55 897345-1400SRM0413-(11-2006)-US-EN...................................................... 61 toc................................................................................. 61 Drive Axle, Speed Reducer, and Differential..................................... 61 Safety Precautions Maintenance and Repair....................................... 62 General......................................................................... 65 Description..................................................................... 65 Drive Axle, Speed Reducer, and Differential Repair.............................. 66 Remove...................................................................... 66 General................................................................. 66 Traction Motor, Speed Reducer, and Differential......................... 67 Motor, Speed Reducer, and Differential, Remove...................... 68 Disassemble................................................................. 70 Speed Reducer........................................................... 70 Differential............................................................ 72 Clean....................................................................... 72 Inspect..................................................................... 72 Assemble.................................................................... 73 Speed Reducer........................................................... 73 Input Gear, Install................................................. 73 New Pinion, Install................................................. 73 Differential............................................................ 76 Drive Axle Housing.......................................................... 79 Remove.................................................................. 79 Clean................................................................... 80 Inspect................................................................. 80 Assemble................................................................ 80 Troubleshooting................................................................. 83 tables.............................................................................. 61 Table 1. Pinion Assembly Shims Adjustment....................................... 75 Table 2. Ring and Pinion Tooth Contact Adjustment............................... 77 897639-1900SRM0559-(02-2009)-US-EN...................................................... 87 toc................................................................................. 87 Hydraulic System................................................................ 87 Safety Precautions Maintenance and Repair....................................... 88 General......................................................................... 93 Description..................................................................... 94 Hydraulic System............................................................ 94 Operation.......................................................................104 Hydraulic System............................................................104 Hydraulic Gear Pump.........................................................115 Rotator Actuator Valve......................................................115 Steering Pump...............................................................115 Hydraulic Tank Repair...........................................................126 Tank, Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108);............126 Tank, Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2............127 Tank, Remove [J2.00-3.20XM (J40-60Z) (B416)]................................128 Hyraulic Tank [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E............128 Inspect.....................................................................130 Small Leaks, Repair.........................................................130 Large Leaks, Repair.........................................................130 Clean.......................................................................130 Steam Method............................................................130 Chemical Solution Method................................................131 Additional Methods for Tank Repair..........................................131 Tank, Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ), (D114, F108............131 Tank, Install [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J............132 Tank, Install [J2.00-3.20XM (J40-65Z) (B416)]...............................132 Filter Replacement..............................................................133 All Lift Trucks Except [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS............133 Remove..................................................................133 Install.................................................................134 Lift Truck Models [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D0............134 Remove..................................................................134 Install.................................................................134 Lift truck Models [E2.00-3.20XM (E45-65Z) (G108) and E1.50-2.00X............135 Remove..................................................................135 Install.................................................................135 Lift Truck Models [J2.00-3.20XM (J40-65Z) (B416)]...........................137 Remove..................................................................137 Install.................................................................137 Hydraulic Pump Repair...........................................................140 Hydraulic Pump, Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D1............140 Hydraulic Pump, Disassemble E1.50-3.20XM (E25-65XM, E25-65XM 2 )............141 Inspect.....................................................................142 Clean.......................................................................142 Pump Seal Replace and Pump Assemble.........................................142 Assemble Pump on Motor......................................................142 Hydraulic Pump and Motor, Install [E1.50-3.20XM (E25-65XM, E25-6............144 Hydraulic Pump, Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A2............145 Hydraulic Pump, Disassemble [E3.50-5.50XL, E4.50XLS (E70-120Z, E............146 Hydraulic Pump, Inspect [E3.50-5.50XL, E4.50XLS (E70-120Z, E100Z............148 Hydraulic Pump, Clean [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)............148 Hydraulic Pump, Assemble [E3.50-5.50XL, E4.50XLS (E70-120Z, E100............148 Hydraulic Pump and Motor, Install [J2.00-3.20XM (J40-60XM, J40-6............148 Main Control Valve Repair.......................................................150 Steering Pump Repair............................................................151 Pump, Remove and Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2............151 Pump, Remove and Disassemble [J2.00-3.20XM (J40-60XM, J40-60XM 2............152 Pump, Assemble and Install..................................................154 Rotary Actuator Valve Repair....................................................155 Disassemble, Clean, and Inspect.............................................155 Assemble....................................................................155 Steering Control Unit Replacement...............................................156 Remove......................................................................156 Install.....................................................................157 Steering Cylinder Repair........................................................163 Main Control Valve Check and Adjust.............................................163 Steering Relief Valve Check and Adjust..........................................164 Specifications..................................................................165 Relief Valve Pressures*.....................................................165 Hydraulic Tank Capacity (dipstick full mark)................................165 Hydraulic Pump Capacities - All Models Except E3.50-5.50XL, E4.5............165 Hydraulic Pump Capacities - Models E3.50-5.50XL, E4.50XLS (E70-1............165 Troubleshooting.................................................................166 Steering....................................................................166 Steering Housing and Steering Control Unit..................................167 Hydraulic System............................................................168 899648-2240SRM0001-(02-2008)-US-EN......................................................173 toc.................................................................................173 Industrial Battery..............................................................173 Safety Precautions Maintenance and Repair.......................................174 General.........................................................................177 Lead-Acid Batteries.............................................................177 Specific Gravity................................................................178 Chemical Reaction in a Cell.....................................................178 Electrical Terms................................................................179 Battery Selection...............................................................180 Battery Voltage.................................................................181 Battery as a Counterweight......................................................181 Battery Ratings.................................................................182 Kilowatt-Hours..............................................................182 Battery Maintenance.............................................................182 Safety Procedures...........................................................182 Maintenance Records.........................................................183 New Battery.................................................................183 Cleaning Battery............................................................183 Adding Water to Battery.....................................................185 Hydrometer..................................................................186 Battery Temperature.........................................................186 Charging Battery............................................................187 Types of Battery Charges................................................188 Methods of Charging.....................................................189 Troubleshooting Charger.................................................190 Knowing When Battery Is Fully Charged...................................190 Where to Charge Batteries...................................................190 Equipment Needed........................................................190 Battery Connectors..........................................................191 Battery Care................................................................191 tables..............................................................................173 Table 1. Battery Capacity Terms.................................................182 899782-2000SRM0077-(02-2009)-US-EN......................................................195 toc.................................................................................195 Manual hydraulic Control Valve..................................................195 Safety Precautions Maintenance and Repair.......................................196 General.........................................................................199 Description.....................................................................199 Operation.......................................................................201 Lift Section................................................................203 Tilt Section................................................................204 Tilt Backward...........................................................204 Tilt Forward............................................................204 Relief Valve............................................................206 Solenoid Valve for Auxiliary Function.......................................207 Main Control Valve Repair.......................................................208 Remove and Disassemble - Control Valve Without OPS Solenoid.................208 Remove and Disassemble - Control Valve With OPS Solenoid....................208 Clean and Inspect...........................................................210 Assemble - Control Valve Without OPS........................................210 Assemble - Control Valve With OPS...........................................210 Install.....................................................................211 Solenoid Valve for Auxiliary Function Repair....................................211 Remove and Disassemble......................................................211 Assemble and Install........................................................213 Troubleshooting.............................................................213 Pressure Relief Valve Check and Adjustment......................................214 Primary Relief Valve........................................................214 Secondary Relief Valve......................................................215 Control Lever Arrangement and Adjustment........................................215 Specifications..................................................................218 Troubleshooting.................................................................219 910442-8000SRM0231-(12-2004)-US-EN......................................................223 toc.................................................................................223 Metric and Inch (SAE) Fasteners.................................................223 Safety Precautions Maintenance and Repair.......................................224 General.........................................................................227 Threaded Fasteners..........................................................227 Nomenclature, Threads.......................................................227 Strength Identification.....................................................228 Cotter (Split) Pins.........................................................228 Fastener Torque Tables......................................................233 Conversion Table............................................................235 tables..............................................................................223 Table 1. Bolts and Screws.......................................................229 Table 2. Studs and Nuts.........................................................230 Table 3. Torque Nuts............................................................231 Table 4. Torque Nuts With Nylon Insert..........................................232 Table 5. Torque Values for Metric Fasteners*....................................233 Table 6. Torque Values for Inch Fasteners*......................................234 Table 7. Conversion Table for Metric and English Units..........................235 Table 8. Cotter Pin Dimensional Data............................................236 Table 9. Cotter Pin Dimensional Data............................................237 Table 10. Cotter Pin Dimensional Data...........................................238 Table 11. Cotter Pin Dimensional Data...........................................240 1459370-1600SRM0720-(11-2006)-US-EN.....................................................245 toc.................................................................................245 Steering Housing and Control Unit...............................................245 Safety Precautions Maintenance and Repair.......................................246 General.........................................................................249 Description.....................................................................249 Operation.......................................................................250 Steering Wheel and Column Assembly Repair.......................................252 Assembly Components, Remove.................................................252 Steering Control Unit, Disassemble..........................................255 Steering Control Unit, Clean................................................257 Steering Control Unit, Assemble.............................................257 Assembly Components, Install................................................259 System Air Removal..............................................................260 Troubleshooting.................................................................261 1534733-1600SRM1054-(11-2006)-US-EN.....................................................265 toc.................................................................................265 Steering System for AC Electric Lift Trucks.....................................265 Safety Precautions Maintenance and Repair.......................................266 General.........................................................................269 Description.....................................................................270 Steering Wheel and Column Assembly Repair.......................................271 General.....................................................................271 Assembly Components, Remove.................................................273 Assembly Components, Install................................................274 Power Steering Motor and Pump...................................................275 Description.................................................................275 Remove......................................................................275 Disassemble.................................................................278 Install.....................................................................278 Power Steering Pump, Repair.................................................278 Seal, Replace...........................................................279 Steering System Air Removal.....................................................280 Steering Pressure Check.........................................................280 Steering Motor Circuits Check...................................................281 Troubleshooting.................................................................282 1534734-2200SRM1055-(11-2007)-US-EN.....................................................287 toc.................................................................................287 Electrical System (Trucks With AC Controllers)..................................287 Safety Precautions Maintenance and Repair.......................................288 General.........................................................................291 Description.....................................................................292 Features of the Display Panels..............................................292 Other Control Components....................................................293 Display Panel and Key Switch Replacement........................................294 Display Panel, Replace......................................................294 Key Switch, Replace.........................................................296 Controller Replacement..........................................................296 Traction and Pump Motor Controller Replacement..............................296 Master Controller, Replace..................................................302 Master Controller, Remove J2.00-3.20XM (J40-60Z) (A416/B416)............302 Master Controller, Install J2.00-3.20XM (J40-60Z) (A416/B416)...........302 Master Controller, Remove E1.50-2.00XM (E25-35Z, E40ZS) (E114/F1........304 Master Controller, Install E1.50-2.00XM (E25-35Z, E40ZS) (E114/F........305 Master Controller, Remove E3.50-5.50XL E4.50XLS (E70-120Z,E100ZS........305 Master Controller, Install E3.50-5.50XL E4.50XLS (E70-120Z,E100Z........305 Control Components Replacement..................................................306 General.....................................................................306 Start Switch, Replace.......................................................306 Brake Light Switch, Replace.................................................307 Seat Switch, Replace........................................................308 Parking Brake Switch, Replace...............................................309 MONOTROL Pedal Direction Switches, Replace..................................311 Steering Column Direction Control Switches, Replace.........................314 Remove..................................................................314 Install.................................................................314 Brake Fluid Switch, Replace.................................................316 Brush Wear and Over Temperature Sensors (DC Pump Motor Only)................316 Rocker Switches for Lights, Replace.........................................316 Accelerator Position Sensor, Replace........................................317 On-Demand Steering Sensor, Replace..........................................318 Lights, Converter, Relay, and Reverse Alarm.................................319 Brake, Tail, and Reverse Light Assembly, Replace........................319 Incandescent Assembly...............................................319 LED Assembly - Remove...............................................321 LED Assembly - Install..............................................323 Strobe Light Assembly, Replace..........................................324 Wire Harness Repair.....................................................325 Del-City Crimp-Solder-Shrink Splice.................................325 Front, Rear Driving Light or Spot Light Assemblies, Replace.............327 Converter, Replace......................................................327 Remove, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)........327 Install, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416).......329 Remove, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108); V30ZMD ....329 Install, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108); V30ZMD....329 Remove, Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100....331 Install, Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E10....331 Reverse Relay, Replace..................................................332 Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416); V30ZMD (D2....332 Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D09....334 Backup Alarm, Replace...................................................334 Horn and Horn Button, Replace...............................................334 Horn Switch and Cover, Replace..........................................335 Hydraulic Pump Switches.....................................................336 Fan Power Supply, Replace...................................................336 Remove, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098/........336 Install, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098........336 Remove, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)............336 Install, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)...........336 Remove, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108).................338 Install, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108)................339 Control and Power Fuse Check....................................................339 Fuse Locations..............................................................339 Brake Light Switch Adjustment...................................................345 Seat Switch Check...............................................................346 Seat Brake Adjustment...........................................................346 Parking Brake Switch Adjustment.................................................347 Direction Switches Check........................................................347 MONOTROL Pedal..............................................................347 Steering Column.............................................................348 MONOTROL Pedal or Accelerator Pedal Adjustment..................................348 Accelerator Position Sensor Adjustment and Start Switch Adjustme................349 Acceleration Position Sensor, Adjust........................................349 Start Switch, Adjust........................................................351 tables..............................................................................287 Table 1. Wire Splice Size.......................................................325 1534735-2200SRM1056-(03-2009)-US-EN.....................................................355 toc.................................................................................355 AC Motor Controllers/Display Panel..............................................355 Safety Precautions Maintenance and Repair.......................................356 Description.....................................................................359 General.....................................................................359 AC Motors...............................................................359 Motor Controllers.......................................................359 Master Controller.......................................................359 Dash Display............................................................359 Controller Area Network Bus (CANbus)....................................359 Master Controller Checks and Adjustments........................................360 Function Settings...............................................................361 General.....................................................................361 Function Numbers............................................................361 Function Descriptions...........................................................364 General.....................................................................364 Function Number 1 BATTERY VOLTAGE.......................................364 Function Number 2 EXTENDED SHIFT........................................364 Function Number 3 ACCELERATION 1........................................364 Function Number 4 ACCELERATION 2........................................364 Function Number 5 TOP SPEED LIMIT.......................................364 Function Number 6 REGEN BRAKING.........................................364 Function Number 7 AUTO DECELERATION.....................................365 Function Number 8 BDI ADJUSTMENT........................................365 Function Number 9 LIFT INTERRUPT........................................365 Function Number 10 POWER STEERING TIME DELAY............................365 Function Number 11 SERVICE REMINDER.....................................365 Function Number 12 CUSTOM...............................................365 Function Number 13 PUMP SPEED 1.........................................365 Function Number 14 PUMP SPEED 2.........................................366 Function Number 15 PUMP SPEED 3.........................................366 Function Number 16 PUMP ACCELERATION....................................366 Troubleshooting.................................................................366 General.....................................................................366 Controller Status Light Emitting Diodes (LEDs)..............................367 Master Controller.......................................................367 AC Motor Controllers....................................................367 Status Codes................................................................373 AC Motor Controllers Status Code Charts.........................................375 Troubleshooting When Dash and/or Lift Truck is not Operational..............396 Typical Symptoms........................................................396 Truck Runs but Dash Display is not Operational, or Only Displays........396 Truck Does Not Run and Dash is Not Operational or Only Displays ........397 Hydraulics Operate Normally, Traction Does Not Operate Correctly........398 Traction Operates Normally, Hydraulics do Not Operate Correctly,........398 AC Transistor Motor Controller Replacement......................................398 General.....................................................................398 General Maintenance Instructions............................................404 Special Precautions.....................................................404 Fuses.......................................................................405 Fan Test....................................................................405 Contactors..................................................................405 Repair..................................................................405 Thermal Sensors.............................................................409 Motor Controller, Replace...................................................409 Display Panel...................................................................410 General.....................................................................410 Premium Display Panel...................................................410 Standard Display Panel..................................................410 Display Functions and Features..................................................411 Key-On Initialization.......................................................411 Standard Display............................................................412 Premium Display.............................................................412 Lift Truck Inspection Function..............................................413 Access to Service Functions.................................................413 Service Functions...........................................................413 Service Functions...........................................................414 Performance Modes...........................................................416 Battery Discharge Indicator (BDI)...........................................416 Hourmeter...................................................................417 Dash Display Service Menu Navigation............................................424 General.....................................................................424 Moving Through Menu Selections..............................................424 Editing and Adding Information..............................................425 tables..............................................................................355 Table 1. Factory Parameters for J2.00-3.20XM (J40-65Z) (A416/B41................361 Table 2. Factory Setting for V30ZMD (D210/E210) and E2.00-3.20XM................362 Table 3. Factory Setting for E1.50-2.00XM (E25-35Z, E40ZS) (E114................362 Table 4. Factory Parameters for E3.50-5.50XL, E4.50XLS (E70-120Z................363 Table 5. List of Status Codes...................................................373 Table 6. 42-Pin Connections/Descriptions for Master Controller..................407 Table 7. Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo................408 Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen................408 1534737-2200SRM1058-(09-2008)-US-EN.....................................................429 toc.................................................................................429 Troubleshooting and Adjustments Using the AC Controls Program (E................429 Safety Precautions Maintenance and Repair.......................................430 General.........................................................................433 Computer Requirements.......................................................433 Software, Install...........................................................433 Language Selection..........................................................433 Demo Mode...................................................................434 Connect PC to Lift Truck....................................................438 Starting AC Controls Program................................................440 Lift Truck Control Setup........................................................444 Change Lift Truck Serial Number or Hourmeter................................444 Setting Factory Default Values or Changing Lift Truck Parameters............446 Create New Custom Lift Truck Configuration..................................452 Lift Truck Configuration Properties.........................................455 Import New Lift Truck Configuration From Disk...............................458 Delete Custom Lift Truck Configuration or Password File.....................460 Dash Display....................................................................463 Custom Display Languages....................................................463 Download Display Language...................................................465 Clear Operator Log..........................................................465 Password Functions..............................................................468 Enable/Disable Password and Lift Truck Inspection Functions.................468 Truck Inspection Checklist..............................................468 Password................................................................468 Password Properties.........................................................468 Create New Password File....................................................473 Download Passwords..........................................................475 Upload Passwords............................................................475 Reports Menu....................................................................479 Devices Report..............................................................479 Custom Report...............................................................479 Password Report.............................................................479 Operator Report.............................................................486 Current Settings Report.....................................................489 Status Code Report..........................................................492 Status Codes Log............................................................495 Troubleshooting.................................................................497 Diagnostics.................................................................497 Help Menu.......................................................................500 General.....................................................................500 Contents....................................................................500 Technical Support...........................................................500 About Electric Truck AC Controls Program....................................500 1556364-0620SRM1098-(11-2006)-US-EN.....................................................507 toc.................................................................................507 AC Motor Repair.................................................................507 Safety Precautions Maintenance and Repair.......................................508 General.........................................................................511 AC Motor Repair.................................................................511 Disassemble.................................................................511 Assemble....................................................................516 Troubleshooting.................................................................518 1580516-2100SRM1139-(07-2008)-US-EN.....................................................521 toc.................................................................................521 Cylinder Repair.................................................................521 Safety Precautions Maintenance and Repair.......................................522 General.........................................................................525 Description.....................................................................525 Safety Procedures When Working Near Mast........................................526 Tilt Cylinder Repair............................................................528 Remove......................................................................528 Disassemble.................................................................528 Inspect.....................................................................529 Clean.......................................................................529 Assemble....................................................................529 Install.....................................................................532 Tilt Cylinders, Adjust......................................................532 Tilt Cylinder Leak Check....................................................534 Torque Specifications.......................................................535 Piston Rod Nut..........................................................535 Gland...................................................................535 Tilt Cylinder Mounting Capscrew.........................................536 Tilt Cylinder Rod End Capscrew..........................................536 Lift Cylinder Repair............................................................536 Main Lift Cylinders.........................................................536 Remove..................................................................536 Disassemble.............................................................537 Clean...................................................................538 Inspect.................................................................538 Assemble................................................................538 Install.................................................................539 Two-Stage FFL Left Side Main Lift Cylinder..................................540 Disassemble.............................................................540 Clean...................................................................542 Inspect.................................................................542 Assemble................................................................542 Install.................................................................542 Free-Lift Cylinder..........................................................542 Remove..................................................................542 Disassemble.............................................................545 Clean...................................................................546 Inspect.................................................................546 Assemble................................................................546 Install.................................................................547 Torque Specifications.......................................................547 Lift Cylinders Leak Check...................................................548 tables..............................................................................521 Table 1. Movement Rates (Maximum) for Tilt Cylinders............................535 1596602-0100SRM1200-(11-2006)-US-EN.....................................................551 toc.................................................................................551 Frame...........................................................................551 Safety Precautions Maintenance and Repair.......................................552 General.........................................................................555 Description.....................................................................555 Overhead Guard Replacement......................................................557 Remove......................................................................557 Install.....................................................................558 Battery and Operator Restraint, Hood and Seat Brake Repair......................559 Battery Restraint and Hood Repair...........................................559 Operator Restraint System and Seat Assembly.................................562 Automatic Locking Retractor (ALR).......................................562 Emergency Locking Retractor (ELR).......................................562 Seat Brake Repair...........................................................563 Counterweight Replacement.......................................................563 Remove......................................................................563 Install.....................................................................564 Traction Motor Repair...........................................................564 Remove......................................................................564 Install.....................................................................565 Hydraulic Tank Repair...........................................................566 Inspect.....................................................................566 Small Leaks, Repair.........................................................566 Large Leaks, Repair.........................................................566 Clean.......................................................................566 Steam Method............................................................567 Chemical Solution Method................................................567 Additional Preparations For Repair..........................................567 Safety Label Replacement........................................................568 Battery Specifications..........................................................570 tables..............................................................................551 Table 1. Torque Values..........................................................558 Table 2. Weight of Counterweights...............................................563 Table 3. Battery Specifications*................................................570 1596603-8000SRM1201-(02-2007)-US-EN.....................................................573 toc.................................................................................573 Periodic Maintenance............................................................573 Safety Precautions Maintenance and Repair.......................................574 General.........................................................................579 How to Move Disabled Lift Truck.............................................579 How to Tow Lift Truck...................................................579 How to Put Lift Trucks on Blocks............................................580 How to Raise Drive Tires................................................580 How to Raise Steering Tires.............................................581 Maintenance Schedule............................................................582 Maintenance Procedures Every 8 Hours or Daily...................................587 General.....................................................................587 How to Make Checks With Key Switch OFF......................................587 Tires and Wheels........................................................587 Forks...................................................................587 Remove..............................................................587 Inspect.............................................................588 Install.............................................................588 Adjust..............................................................588 Inspection of Mast, Mast Pivots, Header Hoses and Lift Chains...........589 Safety Labels...........................................................590 Steering Column Latch...................................................590 Operator Restraint System...............................................590 Automatic Locking Retractor (ALR)...................................590 Emergency Locking Retractor (ELR)...................................590 Battery Restraint System................................................591 Battery.................................................................592 Hydraulic System........................................................593 How to Make Checks With Key Switch ON.......................................594 Horn, Lights, and Alarm.................................................594 Steering System.........................................................595 Service Brakes..........................................................595 Parking Brake...........................................................595 Seat Brake..............................................................595 Control Levers and Pedals...............................................595 Direction and Speed Control Pedals......................................595 Lift System Operation...................................................596 Oil Leaks...............................................................596 First Service After First 100 Hours of Operation................................596 Change Hydraulic Oil and Filter.............................................596 Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (E098)................596 Remove..............................................................596 Install.............................................................598 Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098)................599 Remove..............................................................599 Install.............................................................600 Maintenance Procedures Every 500 Hours or 3 Months..............................601 Wheel Nuts..................................................................601 Header Hose Checks..........................................................601 Mast Lubrication............................................................601 Integral Sideshift Carriage.................................................604 Brake Fluid.................................................................605 Other Lubrication...........................................................605 Maintenance Procedures Every 1000 Hours or 6 Months.............................605 Differential and Speed Reducer..............................................605 Lift Chains.................................................................605 Wear Check..............................................................605 Lubrication.............................................................605 Forks.......................................................................606 Parking Brake...............................................................606 Brake Linkage Shafts........................................................606 Steering Spindles and Tie Rod Ends..........................................607 Seat Rails..................................................................607 Seat Plate Hinges...........................................................607 Electrical Inspection.......................................................607 Contactors..............................................................607 Maintenance Procedures Every 2000 Hours or Yearly...............................609 Brake Fluid.................................................................609 Hydraulic System............................................................610 Hydraulic Tank Breather, Lift Truck Models E3.50-5.50XL (E70-120........610 Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models........610 Remove..............................................................610 Install.............................................................611 Hydraulic Tank Breather, Lift Truck Models E3.50-5.50XL (E70-120........612 Remove..............................................................612 Install.............................................................612 Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models........612 Remove..............................................................612 Install.............................................................612 Differential and Speed Reducer..............................................614 Service Brakes..............................................................614 Wheel Bearings..............................................................615 Steer Wheels, Lubrication...............................................615 Drive Wheels, Lubrication...............................................615 Lift Chains.................................................................615 Battery Maintenance.............................................................615 How to Charge Battery.......................................................615 How to Change Battery.......................................................616 Safety Procedures When Working Near Mast........................................619 Lift and Tilt System Leak Check.................................................622 Check Lift Cylinders for Leaks..............................................622 Check Tilt Cylinders for Leaks..............................................622 Lift Chain Adjustments..........................................................623 Welding Repairs.................................................................624 Overhead Guard Changes..........................................................625 Wheels and Tires................................................................625 General.....................................................................625 Remove Wheels From Lift Truck...............................................625 Remove Tire From Wheel and Install Tire on Wheel............................625 Remove..................................................................625 Install.................................................................625 Install Wheels..............................................................626 tables..............................................................................573 Table 1. Maintenance Schedule...................................................583 Table 2. Battery Specifications*................................................619 Table 3. Hook-Type Carriage Chain Adjustment....................................623 1596604-8000SRM1202-(11-2006)-US-EN.....................................................629 toc.................................................................................629 Capacities and Specifications...................................................629 Safety Precautions Maintenance and Repair.......................................630 Lift Truck Lifting Capacity.....................................................633 Counterweight Weights...........................................................633 Tire Sizes......................................................................633 Capacities......................................................................633 Hydraulic System................................................................634 Steering System.................................................................634 Specifications..............................................................634 Turning Radius..............................................................635 Mast Speeds.....................................................................635 Maximum Carriage and Tilt Creep Rates...........................................636 Battery Specifications..........................................................636 Traction Motor Speed............................................................637 Battery Current at Hoist Relief.................................................637 Torque Specifications...........................................................637 Brake System................................................................637 Differential................................................................638 Drive Axle..................................................................638 Frame.......................................................................638 Mast........................................................................638 Main Control Valve..........................................................638 Steering System.............................................................638 Tilt Cylinders..............................................................639 Hydraulic System............................................................639 Electrical System...........................................................639 tables..............................................................................629 Table 1. Manual Control Valve...................................................634 Table 2. E-Hydraulic Control Valve..............................................634 1596605-8000SRM1203-(02-2009)-US-EN.....................................................643 toc.................................................................................643 Diagrams........................................................................643 Safety Precautions Maintenance and Repair.......................................644 1616865-2000SRM1224-(04-2008)-US-EN.....................................................683 toc.................................................................................683 Electro-Hydraulic Control Valve.................................................683 Safety Precautions Maintenance and Repair.......................................684 General.........................................................................687 Description.....................................................................687 Electro-Hydraulic Control System............................................687 Electro-Hydraulic Control Valve.............................................690 Electro-Hydraulic Valve Driver Module.......................................707 Mini-Lever Module (MLM).....................................................708 Joystick....................................................................709 Electro-Hydraulic Control Valve Repair..........................................709 Remove......................................................................709 Disassemble.................................................................719 Solenoid Coil Replacement...............................................721 Cartridge Replacement...................................................725 Electro-Hydraulic Pressure Reducing Valve (EHPR) Replacement............726 Lift Circuit Check Valve Replacement....................................726 Compensator Cartridge Replacement.......................................727 Primary and Secondary Relief Valves Replacement.........................727 Tilt Counterbalance Valve Replacement...................................727 Flow Regulator Valve Replacement........................................728 Assemble....................................................................728 Install.....................................................................728 E-Hydraulics Calibration....................................................736 Mini-Lever Module...............................................................738 Mini-Lever Module (MLM).....................................................738 Remove..................................................................738 Install.................................................................738 Mini-Lever Replacement......................................................738 Remove..................................................................738 Clean and Inspect.......................................................739 Install.................................................................739 Push Button Switch Replacement..............................................740 Remove..................................................................740 Install.................................................................741 Test........................................................................742 Mini-levers.............................................................742 Full Stroke Test........................................................742 Function Returns to Neutral Test........................................742 Push Button Switch......................................................743 Joystick....................................................................743 Remove and Disassemble..................................................743 Inspect.................................................................743 Assemble and Install....................................................743 Troubleshooting.................................................................744 tables..............................................................................683 Table 1. Primary and Secondary Relief Valve Values..............................693 Table 2. Solenoid Resistance Values.............................................721 Table 3. Cartridge and Solenoid Coil Nut Torque for Lift truck M................725 Table 4. Cartridge and Solenoid Coil Nut Torque for Lift truck M................726 1627340-4000SRM1250-(07-2008)-US-EN.....................................................759 toc.................................................................................759 Mast Repairs....................................................................759 Safety Precautions Maintenance and Repair.......................................760 Safety Procedures When Working Near Mast........................................763 Fork Repair.....................................................................765 Remove......................................................................765 Install.....................................................................766 Checks......................................................................766 Carriage Replacement............................................................767 Remove......................................................................767 Install.....................................................................773 Integral Sideshift Carriage Repair..............................................774 Remove, for lift truck models E3.50-5.50XL, E4.50XLS (E70-120Z, ............774 Disassemble.................................................................774 Assemble....................................................................777 Install, for lift truck models E3.50-5.50XL, E4.50XLS (E70-120Z,............777 Hang On Sideshift Carriage Repair...............................................777 Remove, Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024,............777 Disassemble.................................................................783 Cylinders, Disassemble......................................................786 Sideshift Cylinder......................................................786 Fork Positioner Cylinders...............................................787 Clean and Inspect...........................................................787 Cylinders, Assemble.........................................................788 Fork Positioner Cylinders...............................................788 Sideshift Cylinder......................................................788 Assemble....................................................................788 Install.....................................................................789 Two-Stage Mast With Limited Free-Lift Repair....................................790 Remove......................................................................790 Disassemble.................................................................792 Clean and Inspect...........................................................793 Assemble....................................................................801 Install, H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 10............803 Install, S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT............804 Header Hose Alignment.......................................................813 Two-Stage Mast With Full Free-Lift Repair.......................................822 Remove......................................................................822 Disassemble.................................................................823 Clean and Inspect...........................................................829 Assemble....................................................................830 Install.....................................................................832 Header Hose Installation and Adjustment.....................................837 Installation............................................................837 Adjustment..............................................................837 Three-Stage Mast With Full Free-Lift Repair.....................................838 Remove......................................................................838 Disassemble.................................................................838 Clean and Inspect...........................................................852 Assemble....................................................................853 Install.....................................................................855 Header Hose Alignment for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, ............864 Header Hose Alignment for H6.0FT, H7.0FT (H135FT, H155FT) (H006,............870 Mast Operation Check............................................................875 Tilt Cylinder Adjustment........................................................875 Lift Chains Adjustment..........................................................877 Mast Adjustments................................................................879 Load Roller Adjustment......................................................879 Mast Side Kicking Adjustment................................................881 Carriage Adjustments............................................................881 tables..............................................................................759 Table 1. Fork Tip Alignment.....................................................766 Table 2. Standard Mast Height; Header Hose Tension Mark Location................820 Table 3. Standard Mast Height; Header Hose Tension Mark Location................820 Table 4. Standard Mast Height; Header Hose Tension Mark Location................821 Table 5. Standard Mast Height; Header Hose Tension Mark Location................821 Table 6. Standard Mast Height; Header Hose Tension Mark Location................822 Table 7. Standard Mast Height; Header Hose Tension Mark Location................869 Table 8. Standard Mast Height; Header Hose Tension Mark Location................869 Table 9. Standard Mast Height; Header Hose Tension Mark Location................870 Table 10. Hook-Type Carriage Chain Adjustment...................................878 S01167890999............................................................................885 Page 1..............................................................................885 Page 2..............................................................................886 Page 3..............................................................................887 Page 4..............................................................................888 Page 5..............................................................................889 Page 6..............................................................................890 Page 7..............................................................................891 Page 8..............................................................................892 Page 9..............................................................................893 Page 10.............................................................................894 Page 11.............................................................................895 Page 12.............................................................................896 Page 13.............................................................................897 Page 14.............................................................................898 Page 15.............................................................................899 Page 16.............................................................................900 Page 17.............................................................................901
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