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Hyster E114 (E1.50-2.00XMS) Service Manual – PDF DOWNLOAD
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Hyster E114 (E1.50-2.00XMS) Service Manual – PDF DOWNLOAD
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Description
Hyster E114 (E1.50-2.00XMS) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster E114 (E1.50-2.00XMS) 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 E114 (E1.50-2.00XMS) Service Manual – PDF DOWNLOAD
0100SRM0617-897879(06-2004)-UK-EN....................................................... 1 toc................................................................................. 1 Frame........................................................................... 1 Safety Precautions Maintenance and Repair....................................... 2 General......................................................................... 5 Description..................................................................... 5 Main Frame.................................................................. 5 Other Frame Weldments....................................................... 5 Battery Restraint and Hood Frame............................................ 10 Overhead Guard.............................................................. 11 Overhead Guard Repair........................................................... 15 Remove...................................................................... 15 Install..................................................................... 15 Battery Restraint and Seat Assembly............................................. 17 Counterweight Repair............................................................ 18 Remove...................................................................... 18 Install..................................................................... 19 Traction Motor Repair........................................................... 20 Remove...................................................................... 20 Install..................................................................... 22 Hydraulic Tank Repair........................................................... 23 Inspect..................................................................... 23 Small Leaks, Repair......................................................... 23 Large Leaks, Repair......................................................... 24 Clean....................................................................... 24 Steam Method............................................................ 24 Chemical Solution Method................................................ 24 Additional Preparations for Repair.......................................... 25 Painting Instructions........................................................... 25 Safety Label Replacement........................................................ 26 Battery Specifications.......................................................... 28 tables.............................................................................. 1 Table 1. Counterweights......................................................... 18 0620SRM1098-1556364(06-2004)-UK-EN...................................................... 31 toc................................................................................. 31 AC Motor Repair................................................................. 31 Safety Precautions Maintenance and Repair....................................... 32 General......................................................................... 35 AC Motor Repair................................................................. 35 Disassemble................................................................. 35 Assemble.................................................................... 39 Troubleshooting................................................................. 41 1400SRM0618-897880(06-2004)-UK-EN....................................................... 45 toc................................................................................. 45 Drive Axle, Speed Reducer, and Differential..................................... 45 Safety Precautions Maintenance and Repair....................................... 46 General......................................................................... 49 Description..................................................................... 49 Drive Unit Assembly Repair...................................................... 49 Remove Complete Drive Unit Assembly as a Unit............................... 49 Traction Motor, Remove...................................................... 50 Drive Unit and Speed Reducer, Remove........................................ 52 Drive Axle, Disassemble..................................................... 53 Differential and Speed Reducer, Disassemble................................. 53 Clean....................................................................... 56 Inspect..................................................................... 56 Assembly of Drive Unit.......................................................... 56 Find Correct Shim Set for Hypoid Gear....................................... 56 Pinion, Assemble and Install................................................ 57 Differential and Ring Gear, Assemble and Install............................ 58 Input Gear for Speed Reducer, Assemble...................................... 62 Drive Axle and Hub Assembly, Assemble....................................... 63 Installation of Drive Unit...................................................... 64 Drive Unit, Install......................................................... 64 Traction Motor, Install..................................................... 65 Torque Specifications........................................................... 66 Troubleshooting................................................................. 67 tables.............................................................................. 45 Table 1. Shims Adjustment for Pinion............................................ 57 Table 2. Ring and Pinion Tooth Contact Adjustment............................... 61 1600SRM0619-897881(06-2004)-UK-EN....................................................... 71 toc................................................................................. 71 Steering Axle................................................................... 71 Safety Precautions Maintenance and Repair....................................... 72 General......................................................................... 75 Description..................................................................... 75 Steering Axle Assembly Repair................................................... 76 Remove...................................................................... 76 Install..................................................................... 76 Wheels and Hubs Repair.......................................................... 76 Remove and Disassemble...................................................... 76 Clean....................................................................... 76 Assemble and Install........................................................ 77 Spindles, Bearings, and Links Repair............................................ 78 Remove and Disassemble...................................................... 78 Clean....................................................................... 78 Assemble and Install........................................................ 78 Steering Cylinder Repair........................................................ 80 Remove and Disassemble...................................................... 80 Clean and Inspect........................................................... 81 Assemble and Install........................................................ 82 Torque Specifications........................................................... 82 Troubleshooting................................................................. 83 1600SRM0720-1459370(05-2004)-EN......................................................... 87 toc................................................................................. 87 Steering Housing and Control Unit............................................... 87 Safety Precautions Maintenance and Repair....................................... 88 General......................................................................... 91 Description..................................................................... 91 Operation....................................................................... 92 Steering Wheel and Column Assembly Repair....................................... 93 Assembly Components, Remove................................................. 93 Steering Control Unit, Disassemble.......................................... 96 Steering Control Unit, Clean................................................ 98 Steering Control Unit, Assemble............................................. 98 Assembly Components, Install................................................100 System Air Removal..............................................................102 Troubleshooting.................................................................102 1600SRM1054-1534733-(05-2004)-EN........................................................107 toc.................................................................................107 Steering System for AC Electric Lift Trucks.....................................107 Safety Precautions Maintenance and Repair.......................................108 General.........................................................................111 Description.....................................................................111 Steering Wheel and Column Assembly Repair.......................................113 General.....................................................................113 Assembly Components, Remove.................................................115 Assembly Components, Install................................................116 Power Steering Motor and Pump...................................................117 Description.................................................................117 Remove......................................................................117 Disassemble.................................................................118 Install.....................................................................118 Power Steering Pump, Repair.................................................118 Seal, Replace...........................................................119 Steering System Air Removal.....................................................120 Steering Pressure Check.........................................................120 Steering Motor Circuits Check...................................................121 Troubleshooting.................................................................122 1800SRM0620-897882(06-2004)-UK-EN.......................................................127 toc.................................................................................127 Brake System....................................................................127 Safety Precautions Maintenance and Repair.......................................128 General.........................................................................131 Description and Operation.......................................................131 Service Brakes..............................................................131 Master Cylinder.............................................................131 Parking Brake...............................................................132 Service Brakes Repair...........................................................133 Remove and Disassemble......................................................133 Clean.......................................................................136 Inspect.....................................................................136 Assemble and Install........................................................136 Master Cylinder Repair..........................................................139 Remove......................................................................139 Disassemble.................................................................140 Clean and Inspect...........................................................143 Assemble....................................................................143 Install.....................................................................146 Parking Brake Repair............................................................146 Remove and Dissemble........................................................146 Assemble and Install........................................................146 Parking Brake Switch Replacement................................................148 Brake System Air Removal........................................................149 Service Brakes Adjustment.......................................................149 Brake Pedal Adjustment..........................................................150 Master Cylinder Adjustment......................................................150 Parking Brake Adjustment........................................................150 Parking Brake Switch Adjustment.................................................150 Parking Brake Not Applied Switch Test...........................................151 Seat Brake Assembly.............................................................151 Seat Brake, Adjust - Lift Truck Models E1.50-1.75XM, E2.00XMS (E............151 Brake Switch, Adjust - Lift Truck Models E1.50-1.75XM, E2.00XMS ............151 Electric Seat Brake, Adjust for Lift Truck Model E1.50-2.00XM (E............152 Torque Specifications...........................................................154 Troubleshooting.................................................................154 1900SRM0559-897639-(05-2004)-EN.........................................................161 toc.................................................................................161 Hydraulic System................................................................161 Safety Precautions Maintenance and Repair.......................................162 General.........................................................................165 Description.....................................................................165 Hydraulic System............................................................165 Operation.......................................................................169 Hydraulic System............................................................169 Hydraulic Gear Pump.........................................................169 Rotator Actuator Valve......................................................169 Steering Pump...............................................................173 Hydraulic Tank Repair...........................................................180 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), E1.50-2.00XM ............180 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.00-3.20XM (J4............181 Inspect.....................................................................182 Small Leaks, Repair.........................................................182 Large Leaks, Repair.........................................................182 Clean.......................................................................182 Steam Method............................................................182 Chemical Solution Method................................................183 Additional Methods for Tank Repair..........................................183 E1.50-3.20XM (E25-65XM, E25-65XM 2 ), (D114, F108), E1.50-2.00XM............183 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.00-3.20XM (J4............184 Filter Replacement..............................................................184 Hydraulic Pump Repair...........................................................185 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), N30XMH, and N............185 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216), J2.00-3.20XM (J40-6............186 Pump Seal, Replace and Pump Assemble........................................187 Assemble Pump on Motor......................................................187 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), N30XMH, and N............190 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216), J2.00-3.20XM (J40-6............191 Main Control Valve Repair.......................................................192 Steering Pump Repair............................................................192 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), N30XMH, and N............192 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216), J2.00-3.20XM (J40-6............193 Pump, Assemble and Install..................................................194 Rotary Actuator Valve Repair....................................................196 Disassemble, Clean, and Inspect.............................................196 Assemble....................................................................196 Steering Control Unit Repair....................................................197 Remove......................................................................197 Install.....................................................................197 Steering Cylinder Repair........................................................203 Main Control Valve Check and Adjust.............................................203 Steering Relief Valve Check and Adjust..........................................203 Specifications..................................................................204 Relief Valve Pressures*.....................................................204 Hydraulic Tank Capacity (dipstick full mark)................................204 Hydraulic Pump Capacities...................................................204 Troubleshooting.................................................................205 Steering....................................................................205 Steering Housing and Steering Control Unit..................................206 Hydraulic System............................................................207 2000SRM0562-897642(05-2004)-EN..........................................................213 toc.................................................................................213 Main Control Valve..............................................................213 Safety Precautions Maintenance and Repair.......................................214 General.........................................................................217 Description.....................................................................217 Operation.......................................................................218 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) [D114, F108], E1.50-2.00XM ............220 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) [A216], and J2.00-3.20XM (J............220 Lift Section................................................................220 Tilt Section................................................................220 Tilt Backward...........................................................220 Tilt Forward............................................................221 Relief Valve................................................................222 Main Control Valve Repair.......................................................223 Remove......................................................................223 Disassemble.................................................................223 Clean and Inspect...........................................................223 Assemble....................................................................227 Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), E1.5............227 Install [J2.00-3.20XM (J40-65XM, J40-60XM 2 ) (A216) and J2.00-3............228 Control Lever Linkage Repair....................................................228 Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), E1.50............228 Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), ............228 Assemble and Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114............228 Control Valve Linkage Repair....................................................230 Remove and Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D1............230 Assemble and Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114............230 Control Lever Linkage Repair....................................................231 Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.00-3.............231 Disassemble [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.............231 Assemble and Install [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216............233 Pressure Relief Valve Check and Adjustment......................................234 Primary Relief Valve........................................................234 Secondary Relief Valve......................................................234 Troubleshooting.................................................................235 2100SRM0103-910102(11-2004)-UK-EN.......................................................241 toc.................................................................................241 Tilt Cylinders..................................................................241 Safety Precautions Maintenance and Repair.......................................242 General.........................................................................245 Description.....................................................................245 Tilt Cylinder Repair............................................................245 Remove......................................................................245 Disassemble.................................................................245 Clean.......................................................................245 Assemble....................................................................246 Tilt Cylinders With O-Ring or Single-Lip Seals..........................246 Tilt Cylinders for XM and XMS Models....................................247 Tilt Cylinders for H700-800A and Early Model H700-920B..................248 Install.....................................................................249 Tilt Cylinders Using Chevron Packing....................................249 Install.............................................................251 Tilt Cylinder Leak Check........................................................253 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.............................254 Torque Specifications...........................................................255 Piston Rod Nut..............................................................255 Retainer....................................................................256 Troubleshooting.................................................................257 tables..............................................................................241 Table 1. Movement Rates (Maximum) for Tilt Cylinders............................254 2200SRM1055-1534734(03-2006)-EN.........................................................261 toc.................................................................................261 Electrical System (Trucks With AC Controllers)..................................261 Safety Precautions Maintenance and Repair.......................................262 General.........................................................................265 Description.....................................................................266 Features of the Display Panels..............................................266 Other Control Components....................................................266 Display Panel and Key Switch Replacement........................................268 Display Panel, Replace......................................................268 Key Switch, Replace.........................................................268 Controller Replacement..........................................................270 Traction and Pump Motor Controller, Replace.................................270 Master Controller, Replace..................................................276 Master Controller, Remove J2.00-3.20XM (J40-60Z) (A416/B416)............276 Master Controller, Install J2.00-3.20XM (J40-60Z) (A416/B416)...........276 Master Controller, Remove E1.50-2.00XM (E25-35Z, E40ZS) (E114/F1........276 Master Controller, Install E1.50-2.00XM (E25-35Z, E40ZS) (E114/F........278 Master Controller, Remove E3.50-5.50XL E4.50XLS (E70-120Z, E100Z........278 Master Controller, Install E3.50-5.50XL E4.50XLS (E70-120Z, E100........279 Control Components Replacement..................................................280 General.....................................................................280 Start Switch, Replace.......................................................280 Brake Light Switch, Replace.................................................280 Seat Switch, Replace........................................................281 Parking Brake Switch, Replace...............................................282 MONOTROL Pedal Direction Switches, Replace..................................284 Steering Column Direction Control Switches, Replace.........................286 Remove..................................................................286 Install.................................................................287 Brake Fluid Switch, Replace.................................................287 Brush Wear and Over Temperature Sensors (DC Pump Motor Only)................287 Rocker Switches for Lights, Replace.........................................289 Accelerator Position Sensor, Replace........................................290 On-Demand Steering Sensor, Replace..........................................290 Lights, Converter, Relay, and Reverse Alarm.................................291 Brake, Tail, and Reverse Light Assembly, Replace........................291 Incandescent Assembly...............................................291 LED Assembly, Remove................................................293 LED Assembly, Install...............................................295 Strobe Light Assembly, Replace..........................................296 Wire Harness, Repair....................................................297 Del-City Crimp-Solder-Shrink Splice.................................297 Front, Rear Driving Light or Spot Light Assemblies, Replace.............299 Converter, Replace......................................................299 Remove, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)........299 Install, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416).......301 Remove, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108); V30ZMD ....301 Install, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108); V30ZMD....303 Remove, Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100....303 Install, Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E10....304 Reverse Relay, Replace..................................................304 Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416); V30ZMD (D2....304 Lift Truck Models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D09....306 Backup Alarm, Replace...................................................306 Horn and Horn Button, Replace...............................................306 Horn Switch and Cover, Replace..........................................307 Hydraulic Pump Switches.....................................................307 Fan Power Supply, Replace...................................................308 Remove, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098/........308 Install, Lift Truck Models E3.50-5.50XL (E70-120Z, E100ZS) (D098........308 Remove, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)............308 Install, Lift Truck Models J2.00-3.20XM (J40-65Z) (A416/B416)...........308 Remove, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108).................309 Install, Lift Truck Models E2.00-3.20XM (E45-65Z) (G108)................310 Control and Power Fuse Check....................................................311 Fuse Locations..............................................................311 Brake Light Switch Adjustment...................................................316 Seat Switch Check...............................................................317 Seat Brake Adjustment...........................................................317 Parking Brake Switch Adjustment.................................................317 Direction Switches Check........................................................318 MONOTROL Pedal..............................................................318 Steering Column.............................................................319 MONOTROL Pedal or Accelerator Pedal Adjustment..................................319 Accelerator Position Sensor Adjustment and Start Switch Adjustme................320 Acceleration Position Sensor, Adjust........................................320 Start Switch, Adjust........................................................322 tables..............................................................................261 Table 1. Wire Splice Size.......................................................297 2200SRM1055-1534734(05-2004)-EN.........................................................325 toc.................................................................................325 Electrical System (Trucks With AC Controllers)..................................325 Safety Precautions Maintenance and Repair.......................................326 General.........................................................................329 Description.....................................................................330 Features of the Display Panels..............................................330 Other Control Components....................................................331 Display Panel and Key Switch Replacement........................................331 Display Panel, Replace......................................................331 Key Switch, Replace.........................................................333 Motor Controller Replacement....................................................333 Control Components Replacement..................................................334 Start Switch, Replace.......................................................334 Brake Light Switch, Replace.................................................334 Seat Switch, Replace........................................................335 Parking Brake Switch, Replace...............................................336 MONOTROL Pedal Direction Switches, Replace..................................337 Steering Column Direction Control Switches, Replace.........................338 Brake Fluid Switch, Replace.................................................339 Brush Wear and Overtemperature Sensors (Optional DC Pump Motor O............339 Rocker Switches for Lights, Replace.........................................339 Accelerator Position Sensor, Replace........................................340 On-Demand Steering Sensor, Replace..........................................340 Lights, Converter, Relay, and Reverse Alarm.................................342 Brake, Tail, and Reverse Light Assembly, Replace........................342 Incandescent Assembly...............................................342 LED Assembly - Remove...............................................344 LED Assembly - Install..............................................344 Strobe Light Assembly, Replace..........................................346 Front, Rear Driving Light, or Spot Light Assemblies, Replace............347 Converter, Replace......................................................347 Relay, Replace..........................................................347 Backup Alarm, Replace...................................................348 Horn and Horn Button, Replace...............................................348 Horn Switch and Cover, Replace..........................................349 Hydraulic Pump Switches.....................................................349 Control and Power Fuse Check....................................................349 Fuse Locations..............................................................349 Brake Light Switch Adjustment...................................................354 Seat Switch Check...............................................................355 Seat Brake Adjustment...........................................................355 Parking Brake Switch Adjustment.................................................355 Direction Switches Check........................................................356 MONOTROL Pedal..............................................................356 Steering Column.............................................................356 MONOTROL Pedal or Accelerator Pedal Adjustment..................................357 Accelerator Position Sensor Adjustment and Start Switch Adjustme................357 Acceleration Position Sensor, Adjust........................................357 Start Switch, Adjust........................................................359 2200SRM1056-1534735(03-2006)-EN.........................................................363 toc.................................................................................363 AC Motor Controllers/Display Panel..............................................363 Safety Precautions Maintenance and Repair.......................................364 Description.....................................................................367 General.....................................................................367 AC Motors...............................................................367 Motor Controllers.......................................................367 Master Controller.......................................................367 Dash Display............................................................367 Controller Area Network Bus (CANBus)....................................368 Master Controller Checks and Adjustments........................................368 Function Settings...............................................................369 General.....................................................................369 Function Numbers............................................................369 Function Descriptions...........................................................372 General.....................................................................372 Function Number 1 BATTERY VOLTAGE.......................................372 Function Number 2 EXTENDED SHIFT........................................372 Function Number 3 ACCELERATION 1........................................372 Function Number 4 ACCELERATION 2........................................372 Function Number 5 TOP SPEED LIMIT.......................................372 Function Number 6 REGEN BRAKING.........................................372 Function Number 7 AUTO DECELERATION.....................................373 Function Number 8 BDI ADJUSTMENT........................................373 Function Number 9 LIFT INTERRUPT........................................373 Function Number 10 POWER STEERING TIME DELAY............................373 Function Number 11 SERVICE REMINDER.....................................373 Function Number 12 CUSTOM...............................................373 Function Number 13 PUMP SPEED 1.........................................373 Function Number 14 PUMP SPEED 2.........................................374 Function Number 15 PUMP SPEED 3.........................................374 Function Number 16 PUMP ACCELERATION....................................374 Troubleshooting.................................................................374 General.....................................................................374 Controller Status Light Emitting Diodes (LEDs)..............................375 AC Master Controller....................................................375 AC Motor Controllers....................................................375 Status Codes................................................................381 AC Motor Controllers Status Code Charts.........................................383 AC Transistor Motor Controller Replacement......................................402 General.....................................................................402 General Maintenance Instructions............................................408 Special Precautions.....................................................408 Fuses.......................................................................409 Fan Test....................................................................409 Contactors..................................................................409 Repair..................................................................410 Thermal Sensors.............................................................413 Motor Controller, Replace...................................................413 Display Panel...................................................................414 General.....................................................................414 Premium Display Panel...................................................414 Standard Display Panel..................................................414 Display Functions and Features..................................................415 Key-On Initialization.......................................................415 Standard Display............................................................416 Premium Display.............................................................416 Lift Truck Inspection Function..............................................417 Access to Service Functions.................................................417 Service Functions...........................................................417 Service Functions...........................................................418 Performance Modes...........................................................420 Battery Discharge Indication (BDI)..........................................420 Hourmeter...................................................................421 Dash Display Service Menu Navigation............................................425 General.....................................................................425 Moving Through Menu Selections..............................................425 Editing and Adding Information..............................................426 tables..............................................................................363 Table 1. Factory Parameters for J2.00-3.20XM (J40-65Z) (A416/B41................369 Table 2. Factory Setting for V30ZMD (D210/E210) and E2.00-3.20XM................370 Table 3. Factory Setting for E1.50-2.00XM (E25-35Z, E40ZS) (E114................370 Table 4. Factory Parameters for E3.50-5.50XL, E4.50XLS (E70-120Z................371 Table 5. List of Status Codes...................................................381 Table 6. 42-Pin Connections/Descriptions for Master Controller..................411 Table 7. Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo................412 Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen................412 2200SRM1056-1534735(05-2004)-EN.........................................................429 toc.................................................................................429 AC Motor Controllers/ Display Panel.............................................429 Safety Precautions Maintenance and Repair.......................................430 Description.....................................................................433 General.....................................................................433 AC Motors...............................................................433 Motor Controllers.......................................................433 Master Controller.......................................................433 Dash Display............................................................433 Controller Area Network Bus (CAN Bus)...................................433 Master Controller Checks and Adjustments........................................434 Function Parameters.............................................................434 General.....................................................................434 Function Numbers............................................................436 Function Parameter Descriptions.................................................436 General.....................................................................436 Function Number 1 BATTERY VOLTAGE.......................................436 Function Number 2 EXTENDED SHIFT........................................436 Function Number 3 ACCELERATION 1........................................436 Function Number 4 ACCELERATION 2........................................437 Function Number 5 TOP SPEED LIMIT.......................................437 Function Number 6 REGEN BRAKING.........................................437 Function Number 7 AUTO DECELERATION.....................................437 Function Number 8 BDI ADJUSTMENT........................................437 Function Number 9 LIFT INTERRUPT........................................437 Function Number 10 POWER STEERING TIME DELAY............................437 Function Number 11 SERVICE REMINDER.....................................437 Function Number 12 CUSTOM...............................................438 Function Number 13 PUMP SPEED 1.........................................438 Function Number 14 PUMP SPEED 2.........................................438 Function Number 15 PUMP SPEED 3.........................................438 Function Number 16 PUMP ACCELERATION....................................438 Troubleshooting.................................................................439 General.....................................................................439 Controller Status Light Emitting Diodes (LEDs)..............................439 AC Master Controller....................................................439 AC Motor Controllers....................................................440 Status Codes................................................................444 AC Motor Controllers Status Code Charts.........................................445 AC Transistor Motor Controller Repair...........................................461 General.....................................................................461 General Maintenance Instructions............................................465 Special Precautions.....................................................465 Fuses.......................................................................466 Fan Test....................................................................466 Contactors..................................................................466 Repair..................................................................466 Thermal Sensors.............................................................470 Motor Controller, Replace...................................................470 Display Panel...................................................................471 General.....................................................................471 Premium Display Panel...................................................471 Standard Display Panel..................................................471 Display Functions and Features..................................................472 Key-ON Initialization.......................................................472 Standard Display............................................................473 Premium Display.............................................................473 Lift Truck Inspection Function..............................................474 Access to Service Functions.................................................474 Service Functions...........................................................474 Performance Modes...........................................................475 Battery Discharge Indication (BDI)..........................................476 Hourmeter...................................................................476 Dash Display Service Menu Navigation............................................477 General.....................................................................477 Moving Through Menu Selections..............................................477 Editing and Adding Information..............................................477 tables..............................................................................429 Table 1. Factory Parameter Table - J2.00-3.20XM (J40-65Z) (A416)................434 Table 2. Factory Parameter Table - V30ZMD (D210), E2.00-3.20XM (................435 Table 3. Factory Parameter Table - E1.50-2.00XM (E25-35Z, E40ZS)................435 Table 4. List of Status Codes...................................................444 Table 5. 42-Pin Connections/Descriptions for Master Controller..................468 Table 6. Pin Connections/Descriptions for 72/80 Volt Motor Contr................469 Table 7. Pin Connections/Descriptions for 36/48 Volt Motor Contr................470 2200SRM1058-1534737(05-2004)-EN.........................................................481 toc.................................................................................481 Troubleshooting and Adjustments Using the AC Controls Program...................481 Safety Precautions Maintenance and Repair.......................................482 General.........................................................................485 Computer Requirements.......................................................485 Software, Install...........................................................485 Language Selection..........................................................485 Demo Mode...................................................................486 Connect PC to Lift Truck....................................................488 Starting AC Controls Program................................................489 Lift Truck Control Setup........................................................493 Change Lift Truck Serial Number or Hourmeter................................493 Setting Factory Default Values or Changing Lift Truck Parameters............494 Create New Custom Lift Truck Configuration..................................498 Lift Truck Configuration Properties.........................................502 Import New Lift Truck Configuration From Disk...............................504 Delete Custom Lift Truck Configuration or Password File.....................506 Dash Display....................................................................508 Custom Display Languages....................................................508 Download Display Language...................................................510 Clear Operator Log..........................................................512 Clear Status Log............................................................513 Password Functions..............................................................514 Enable/Disable Password and Lift Truck Inspection Functions.................514 Truck Inspection Checklist..............................................514 Password................................................................514 Password Properties.........................................................514 Create New Password File....................................................519 Download Passwords..........................................................520 Upload Passwords............................................................522 Reports Menu....................................................................524 Passwords...................................................................524 Status Codes................................................................527 Operators...................................................................530 Current Settings............................................................533 Troubleshooting.................................................................536 Diagnostics.................................................................536 Help Menu.......................................................................539 General.....................................................................539 Contents....................................................................539 Technical Support...........................................................541 About Electric Truck AC Controls Program....................................541 2240SRM001-899648(11-2003)-EN...........................................................547 toc.................................................................................547 Industrial Battery..............................................................547 Safety Precautions Maintenance and Repair.......................................548 General.........................................................................551 Lead-Acid Batteries.............................................................551 Specific Gravity................................................................552 Chemical Reaction in a Cell.....................................................552 Electrical Terms................................................................553 Battery Selection...............................................................554 Battery Voltage.................................................................555 Battery as a Counterweight......................................................555 Battery Ratings.................................................................555 Kilowatt-Hours..............................................................555 Battery Maintenance.............................................................556 Safety Procedures...........................................................556 Maintenance Records.........................................................556 New Battery.................................................................556 Cleaning Battery............................................................557 Adding Water to Battery.....................................................558 Hydrometer..................................................................559 Battery Temperature.........................................................559 Charging Battery............................................................560 Types of Battery Charges................................................561 Methods of Charging.....................................................562 Troubleshooting Charger.................................................563 Knowing When Battery Is Fully Charged...................................563 Where to Charge Batteries...................................................563 Equipment Needed........................................................563 Battery Connectors..........................................................564 Battery Care................................................................564 tables..............................................................................547 Table 1. Battery Capacity Terms.................................................555 4000SRM521-897506(05-2004)-EN...........................................................569 toc.................................................................................569 Mast............................................................................569 Safety Precautions Maintenance and Repair.......................................570 General.........................................................................573 Description and Operation.......................................................573 Carriages...................................................................573 Mast Mounts.................................................................575 Two-Stage Mast, Limited Free-Lift (LFL).........................................577 Description and Operation...................................................577 Two-Stage Mast, Full Free-Lift (FFL)............................................578 Description and Operation...................................................578 Three-Stage Mast, Full Free-Lift (FFL)..........................................580 Description and Operation...................................................580 Cylinder Cushion During Lifting Sequence........................................583 Cylinder Cushion During Lowering Sequence.......................................584 4000SRM522-897507(05-2004)-EN...........................................................587 toc.................................................................................587 Mast............................................................................587 Safety Precautions Maintenance and Repair.......................................588 General.........................................................................591 Safety Procedures When Working Near Mast........................................591 Forks Repair....................................................................593 Remove......................................................................593 Install.....................................................................594 Carriages Repair................................................................594 Standard Carriage, Remove...................................................594 Hang-On Sideshift Carriage, Remove..........................................595 Standard Carriage and Hang-On Sideshift Carriage, Repair....................596 Standard Carriage, Install..................................................596 Hang-On Sideshift Carriage, Install.........................................597 Integral Sideshift Carriage.................................................597 Remove..................................................................597 Clean and Inspect.......................................................599 Repair..................................................................599 Install.................................................................600 Mast Repair.....................................................................600 Remove......................................................................600 Two-Stage LFL and Two-Stage FFL Masts, Disassemble..........................602 Three-Stage FFL Mast........................................................609 Disassemble.............................................................609 Mast and Chains, Clean and Inspect......................................612 Two-Stage LFL and Two-Stage FFL Mast, Assemble..............................613 Three-Stage FFL Mast, Assemble..............................................614 Install.....................................................................616 Lift Cylinders Repair...........................................................617 Main Lift Cylinders, Remove.................................................617 Free-Lift Cylinder, Remove..................................................617 Lift Cylinders, Disassemble.................................................618 Lift Cylinders, Assemble....................................................618 Main Lift Cylinders, Install................................................621 Free-Lift Cylinder, Install.................................................622 Header Hose Arrangements........................................................622 Two-Stage LFL Mast, New Hose Install........................................622 Two-Stage LFL Mast, Adjust Hoses After Installation.........................628 Two-Stage FFL Mast, New Hose Install........................................628 Two-Stage FFL Mast, Adjust Hoses After Installation.........................633 Three-Stage FFL Mast, New Hose Install......................................635 Three-Stage FFL Mast, Adjust Hoses After Installation.......................645 Header Hose Arrangement.........................................................646 Two-Stage LFL Mast, New Hose Install........................................646 Two-Stage LFL Mast, Adjust Hoses After Installation.........................646 Two-Stage FFL Mast, New Hose Install........................................650 Two-Stage FFL Mast, Adjust Hoses After Installation.........................655 Three-Stage FFL Mast, New Hose Install......................................657 Three-Stage FFL Mast, Adjust Hoses After Install............................662 Lift and Tilt System Leak Check.................................................666 Lift Cylinders Leak Check...................................................666 Tilt Cylinders Leak Check...................................................666 Tilt Cylinders Adjustment.......................................................667 Lift Chains Adjustment..........................................................668 Mast Adjustment.................................................................670 Carriage Adjustment.............................................................672 Troubleshooting.................................................................672 tables..............................................................................587 Table 1. Hook-Type Carriage Chain Adjustment....................................669 Table 2. Pin-Type Carriage Chain Adjustment.....................................669 8000SRM0231-910442(03-2004)-EN..........................................................677 toc.................................................................................677 Metric and Inch (SAE) Fasteners.................................................677 Safety Precautions Maintenance and Repair.......................................678 General.........................................................................681 Threaded Fasteners..........................................................681 Nomenclature, Threads.......................................................681 Strength Identification.....................................................682 Cotter (Split) Pins.........................................................682 Fastener Torque Tables......................................................687 Conversion Table............................................................689 tables..............................................................................677 Table 1. Bolts and Screws.......................................................683 Table 2. Studs and Nuts.........................................................684 Table 3. Torque Nuts............................................................685 Table 4. Torque Nuts With Nylon Insert..........................................686 Table 5. Torque Values for Metric Fasteners*....................................687 Table 6. Torque Values for Inch Fasteners*......................................688 Table 7. Conversion Table for Metric and English Units..........................689 Table 8. Cotter Pin Dimensional Data............................................690 Table 9. Cotter Pin Dimensional Data............................................691 Table 10. Cotter Pin Dimensional Data...........................................692 Table 11. Cotter Pin Dimensional Data...........................................694 8000SRM1059-1534738(03-2006)-EN.........................................................697 toc.................................................................................697 Electrical Diagrams.............................................................697 Safety Precautions Maintenance and Repair.......................................698 8000SRM1059-1534738(05-2004)-EN.........................................................759 toc.................................................................................759 Electrical Diagrams.............................................................759 Safety Precautions Maintenance and Repair.......................................760 8000SRM1060-1534739(06-2004)-UK-EN......................................................805 toc.................................................................................805 Periodic Maintenance............................................................805 Safety Precautions Maintenance and Repair.......................................806 General.........................................................................811 Serial Number Data..........................................................811 How to Move Disabled Lift Truck.............................................811 How to Tow Lift Truck...................................................811 How to Put Lift Truck on Blocks.............................................812 How to Raise Drive Tires................................................812 How to Raise Steering Tires.............................................813 Maintenance Schedule............................................................813 Maintenance Procedures Every 8 Hours or Daily...................................824 How to Make Checks With Key OFF.............................................824 Tires and Wheels........................................................824 Forks...................................................................825 Adjust..............................................................825 Remove..............................................................825 Install.............................................................826 Forks, Mast, and Lift Chains, Inspect...................................826 Safety Labels...........................................................827 Steering Column Latch...................................................827 Operator Restraint System...............................................827 Battery Restraint System V30ZMD (D210), E1.50-2.00XM (E25-35Z, E........828 Battery Restraint System J2.00-3.20XM (J40-65Z) (A416) Lift Truc........829 Battery.................................................................829 Hydraulic System........................................................830 How to Make Checks With Key ON..............................................830 Gauges, Horn, and Fuses.................................................831 Steering System.........................................................831 Service Brakes..........................................................831 Parking Brake...........................................................831 Control Levers and Pedals...............................................831 Direction and Speed Control Pedals......................................831 Lift System Operation...................................................832 Maintenance Procedures Every 250 Hours or 6 Weeks...............................832 Steering Tie Rods...........................................................832 Steering King Pins, E1.50-2.00XM (E114) Trucks Only.........................832 Maintenance Procedures Every 500 Hours or 3 Months..............................833 Differential and Speed Reducer, V30ZMD (D210), E2.00-3.20XM (E45............833 Wheel Nut Torques...........................................................834 Mast........................................................................834 Forks.......................................................................835 Brake Fluid, V30ZMD (D210), E1.50-2.00XM (E25-35Z, E40ZS) (E114)............835 Parking Brake Adjustment....................................................835 Maintenance Procedures Every 1000 Hours or 6 Months.............................835 Lift Chains.................................................................835 Lift Chains.................................................................835 Wear Check..............................................................835 Forks.......................................................................836 Check Upper and Lower Bearings, Integral Sideshift Carriage.................836 Steering Tie Rods, All Models Except E1.50-2.00XM (E114)....................837 Steering Axle Spindles......................................................837 King Pins, All Models Except E1.50-2.00XM (E114)........................837 Hydraulic Tank Breather.....................................................837 Differential and Speed Reducer J2.00-3.20XM (J40-65Z) (A416) Lif............837 Brake Fluid, J2.00-3.20XM (J40-65Z) (A416) Lift Truck Models................837 Electrical Inspection.......................................................838 Contactors..............................................................838 Motor Brushes (Optional DC Pump)........................................839 Motor Brushes, General..............................................839 Other Lubrication...........................................................841 Maintenance Procedures Every 2000 Hours or Yearly...............................841 Hydraulic System............................................................841 Change Filter for Hydraulic Oil.........................................841 Change Hydraulic Oil....................................................842 Differential and Speed Reducer..............................................842 Service Brakes..............................................................843 Wheel Bearings..............................................................843 Steer Wheels, Lubrication...............................................843 Drive Wheels, Lubrication...............................................843 Lift Chains.................................................................843 Replace Upper and Lower Bearings, Integral Sideshift Carriage...............844 Other Lubrication...........................................................844 Battery Maintenance.............................................................844 How to Charge Battery.......................................................844 How to Change Battery for the J2.00-3.20XM (J40-65Z) (A416) Lift............845 General.................................................................845 How to Change Battery for the V30ZMD (D210), E1.50-2.00XM (E25-3............847 General.................................................................847 Lift and Tilt System Leak Check.................................................850 Lift Cylinders Leak Check...................................................850 Tilt Cylinders Leak Check...................................................851 Safety Procedures When Working Near Mast........................................851 Lift Chain Adjustments..........................................................853 Welding Repairs.................................................................854 Overhead Guard Changes..........................................................855 Wheels and Tire Maintenance.....................................................855 Tires and Wheels, J2.00-3.20XM (J40-65Z) (A416), V30ZMD (D210), ............855 Remove Wheels From Lift Truck...........................................855 Remove and Install Tire on Wheel........................................855 Pneumatic Tires and Wheels J2.00-3.20XM (J40-65Z) (A416)....................856 Remove Wheels From Lift Truck...........................................856 Remove Wheel From Pneumatic Tire........................................857 Install Wheel in Pneumatic Tire.........................................858 Install Three- or Four-Piece Wheel in Pneumatic Tire....................859 Add Air to Tires........................................................860 Wheels, Install.........................................................860 Solid Rubber Tires on Pneumatic Wheels......................................861 Remove Wheels From Lift Truck...........................................861 Remove Solid Rubber Tire From Pneumatic Wheel...........................861 Install Solid Rubber Tire on Pneumatic Wheel............................863 Wheels, Install.........................................................864 Solid Rubber Tire, Change...................................................864 Remove and Install Tire on Wheel........................................864 Remove Wheel From Tire..................................................866 Install Wheel in Tire...................................................867 SIT Tire, Change............................................................869 Remove SIT Solid Tire From Wheel........................................869 Install SIT Solid Tire on Wheel.........................................870 Adhesives and Sealants..........................................................871 tables..............................................................................805 Table 1. Maintenance Schedule...................................................815 8000SRM1113-1565454(06-2004)-UK-EN......................................................875 toc.................................................................................875 Capacities and Specifications...................................................875 Safety Precautions Maintenance and Repair.......................................876 Wheels and Tires................................................................879 Counterweights..................................................................879 Hydraulic System................................................................880 Capacities......................................................................880 Battery Specifications..........................................................881 Battery Height Specifications (Hoods and Battery Types).....................882 Maximum Carriage and Tilt Creep Rates...........................................883 Mast Speeds.....................................................................884 E25-35Z, E40ZS Mast Speeds (36 and 48 Volt) Americas........................884 E1.50-2.00XM Mast Speeds (48 Volt) Europe...................................885 Torque Specifications...........................................................886 Frame.......................................................................886 Mast........................................................................886 Drive Axle, Speed Reducer, and Differential.................................887 Steering Axle...............................................................887 Brake.......................................................................887 Adhesives and Sealants..........................................................888
HYSTER E114 (E1.50-2.00XMS) SERVICE MANUAL – PDF DOWNLOAD:
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