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Hyster F108 Service Manual – PDF DOWNLOAD
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Description
Hyster F108 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F108 Service Manual – PDF DOWNLOAD
SAFEΠ’Y PRECAUTIONS MAINTENANCE AND REPAIR :
β’ When lifting parts or assemΠ«ies, make sure that all slings, chains or ΡΠ°Π«Π΅s are
correctly fastened and that the load being lifted is balanced. Make sure that the
crane, ΡΠ°Π«Π΅s and chains have the capacity to support the weight of the load.
β’ Do not lift heavy parts Π¬Ρ hand. Use Π° lifting mechanism.
β’ Wear safety glasses.
β’ DISCONNECΠ’ Π’ΠΠ ΠΠΠ’Π’ΠRΠ£ CONNECΠOR before doing any
maintenance or repair ΠΎΠΏ electric lift trucks. Disconnect the battery ground ΡΠ°Π«Π΅
ΠΎΠΏ intemal combustion lift trucks.
β’ Always use ΡΠΎΠΏΠ΅Ρt Π«ocks to prevent the unit from rolling or falling. See “How
Π’ΠΎ Put The Lift Truck ΠΠΏ Blocks” in the OPERAΠNG ΠANUAL or the
PERIODIC ΠAINΠ’ENANCE section.
β’ ΠΠ΅Π΅Ρ the unit and working area clean and in order.
β’ Use the correct tools for the job.
β’ ΠΠ΅Π΅Ρ the tools clean and in good condition.
β’ Always use HYSTERAPPROVED parts when making repairs. Replacement
parts must meet or exceed the specifications of the original equipment
manufacturer.
β’ Make sure that all nuts, bolts, snap rings and other fastening devices are
removed before using force to remove parts.
β’ Always fasten Π° DO NOT ΠΠ ΠRΠΠ’Π sign to the controls of the unit when
making repairs or if the unit needs repairs.
β’ Make sure you follow the WARNING and CAUΠ’ION notes in the instructions.
β’ Batteries generate flammaΠ«e gas when they are being charged. ΠΠ΅Π΅Ρ fire and
sparks away from the area. Make sure the area has ventilation.
TABLE OF CONTENTS:
Hyster F108 Service Manual – PDF DOWNLOAD
897409-2200SRM0460...................................................................... 1 .................................................................................... 1 .................................................................................... 2 .................................................................................... 3 .................................................................................... 4 .................................................................................... 5 .................................................................................... 6 .................................................................................... 7 .................................................................................... 8 .................................................................................... 9 .................................................................................... 10 .................................................................................... 11 .................................................................................... 12 .................................................................................... 13 .................................................................................... 14 .................................................................................... 15 .................................................................................... 16 .................................................................................... 17 .................................................................................... 18 .................................................................................... 19 .................................................................................... 20 .................................................................................... 21 .................................................................................... 22 .................................................................................... 23 .................................................................................... 24 .................................................................................... 25 .................................................................................... 26 .................................................................................... 27 .................................................................................... 28 .................................................................................... 29 .................................................................................... 30 .................................................................................... 31 .................................................................................... 32 .................................................................................... 33 .................................................................................... 34 .................................................................................... 35 .................................................................................... 36 .................................................................................... 37 .................................................................................... 38 .................................................................................... 39 .................................................................................... 40 .................................................................................... 41 .................................................................................... 42 .................................................................................... 43 .................................................................................... 44 .................................................................................... 45 .................................................................................... 46 .................................................................................... 47 .................................................................................... 48 .................................................................................... 49 .................................................................................... 50 .................................................................................... 51 .................................................................................... 52 .................................................................................... 53 .................................................................................... 54 .................................................................................... 55 .................................................................................... 56 .................................................................................... 57 .................................................................................... 58 .................................................................................... 59 .................................................................................... 60 .................................................................................... 61 .................................................................................... 62 .................................................................................... 63 .................................................................................... 64 .................................................................................... 65 .................................................................................... 66 .................................................................................... 67 .................................................................................... 68 .................................................................................... 69 .................................................................................... 70 .................................................................................... 71 .................................................................................... 72 .................................................................................... 73 .................................................................................... 74 .................................................................................... 75 .................................................................................... 76 .................................................................................... 77 .................................................................................... 78 .................................................................................... 79 .................................................................................... 80 .................................................................................... 81 .................................................................................... 82 .................................................................................... 83 .................................................................................... 84 .................................................................................... 85 .................................................................................... 86 .................................................................................... 87 .................................................................................... 88 897596-8000SRM0551-(08-2003)-US......................................................... 89 toc................................................................................. 89 Electrical Diagrams............................................................. 89 Safety Precautions Maintenance and Repair....................................... 90 897596-8000SRM0551-(08-2003)-US-EN...................................................... 155 toc................................................................................. 155 Electrical Diagrams............................................................. 155 Safety Precautions Maintenance and Repair....................................... 156 897636-2200SRM0557-(08-2003)-US......................................................... 221 toc................................................................................. 221 EV-100ZXβ’ SCR Motor Controller.................................................. 221 Safety Precautions Maintenance and Repair....................................... 222 General......................................................................... 227 Model Number Data For EV-100ZX Controller................................... 228 Register Parameters............................................................. 242 General..................................................................... 242 Function Numbers............................................................ 242 Control Card, Checks and Adjustments............................................ 242 Handset......................................................................... 243 How to Check and Adjust Registers........................................... 243 How to Scroll through Fault Codes and Clear Them............................ 243 Checks and Adjustments on Workbench......................................... 244 When Handset Is Connected to Control Card Installed In Lift Truc............ 245 Function Numbers 1 through 15............................................... 246 Function Numbers 16 through 30.............................................. 246 Function Numbers 48 through 62.............................................. 246 Control Cards................................................................... 247 Function Number Descriptions................................................ 247 Traction Control Cards (Label Letters - ZH and ZY).......................... 247 Function Number 1 STORED STATUS CODE.................................... 247 Function Number 2 CREEP SPEED........................................... 248 Function Number 3 CONTROLLED ACCELERATION AND 1A TIME................... 248 Function Number 4 CURRENT LIMIT......................................... 248 Function Number 5 PLUGGING DISTANCE (CURRENT)........................... 248 Function Number 6 1A DROP OUT CURRENT................................... 248 Function Number 7 FIELD WEAKENING PICK UP............................... 248 Function Number 8 FIELD WEAKENING DROP OUT.............................. 249 Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT.................... 249 Function Number 10 REGENERATIVE BRAKING START........................... 249 Function Number 13 SPEED LIMIT 3 (SL3).................................. 249 Function Number 14 INTERNAL RESISTANCE COMPENSATION..................... 250 Function Number 15 BATTERY VOLTS........................................ 250 Function Numbers GREATER THAN 15........................................ 250 Function Number 16 PEDAL POSITION PLUG.................................. 250 Function Number 17 CARD TYPE SELECTION.................................. 251 Function Number 18 STEERING PUMP TIME DELAY............................. 251 Function Number 19 MAINTENANCE ALERT (Tens/Units)....................... 251 Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)............... 251 Function Number 21 MAINTENANCE SPEED LIMIT.............................. 251 Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS................. 251 Function Number 29 HOURMETER (Tens/Units)............................... 252 Function Number 30 HOURMETER (Thousands/Hundreds)....................... 252 Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE................ 252 Function Number 48 CONTROLLED ACCELERATION AND 1A TIME.................. 252 Function Number 49 FIELD WEAKENING PICK UP.............................. 252 Function Number 50 SPEED LIMIT 1........................................ 252 Function Number 52 CONTROLLED ACCELERATION AND 1A TIME.................. 253 Function Number 53 FIELD WEAKENING PICK UP.............................. 253 Function Number 54 SPEED LIMIT 1........................................ 253 Function Number 56 CONTROLLED ACCELERATION AND 1A TIME.................. 253 Function Number 57 FIELD WEAKENING PICK UP.............................. 253 Function Number 58 SPEED LIMIT 1........................................ 253 Function Number 60 CONTROLLED ACCELERATION AND 1A TIME.................. 254 Function Number 61 FIELD WEAKENING PICK UP.............................. 254 Pump Control Card (Label Letter ZP)......................................... 254 Function Number 1 STORED STATUS CODE.................................... 254 Function Number 2 INTERNAL RESISTANCE COMPENSATION START................ 254 Function Number 3 CONTROLLED ACCELERATION............................... 254 Function Number 4 CURRENT LIMIT......................................... 254 Function Number 7 CONTROLLED ACCELERATION COMPENSATION.................. 254 Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and S........ 255 Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lif........ 255 Function Number 13 SPEED LIMIT 3 (SL3).................................. 255 Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift........................ 255 Function Numbers Greater Than 15........................................ 255 Function Number 16 INTERNAL RESISTANCE COMPENSATION..................... 255 Function Number 17 CARD TYPE SELECTION.................................. 256 Function Numbers 18 through 28 TEMPORARY DATA REGISTERS................. 256 Function Number 29 HOURMETER (Tens/Units)............................... 256 Function Number 30 HOURMETER (Thousands/Hundreds)....................... 256 Function Number 48 CONTROLLED ACCELERATION.............................. 256 Function Number 49 SPEED LIMIT 2........................................ 256 Function Number 50 SPEED LIMIT 3........................................ 256 Function Number 52 CONTROLLED ACCELERATION.............................. 256 Function Number 53 SPEED LIMIT 2........................................ 257 Function Number 54 SPEED LIMIT 3........................................ 257 Function Number 56 CONTROLLED ACCELERATION.............................. 257 Function Number 57 SPEED LIMIT 2........................................ 257 Function Number 58 SPEED LIMIT 3........................................ 257 Function Number 60 CONTROLLED ACCELERATION.............................. 257 Function Number 61 SPEED LIMIT 2........................................ 257 Function Number 62 SPEED LIMIT 3........................................ 257 Register Parameters......................................................... 257 Troubleshooting................................................................. 258 General..................................................................... 258 Status Codes................................................................ 259 Register Maps............................................................... 261 Status Code Charts.............................................................. 272 EV-100ZX SCR Motor Controller Repair............................................ 314 Fuses....................................................................... 316 SCR, Check.................................................................. 316 SCR Assembly................................................................ 316 Thermal Protector........................................................... 317 SCR 1 Assembly, Replace..................................................... 317 OFF Circuit for SCR 1....................................................... 317 Reactor Assembly, Check................................................. 317 Suppressors for SCR 2 and SCR 5, Check.................................. 317 SCR 2 and SCR 5, Check.................................................. 318 SCR 2 and SCR 5, Replace................................................ 318 Capacitor C1, Check..................................................... 318 Diodes D3 and D4............................................................ 318 Diodes D3 and D4, Check................................................. 319 Diodes D3 and D4, Replace............................................... 319 Motor Current Sensor........................................................ 319 Contactors.................................................................. 319 Contactor, Repair....................................................... 320 Control Card................................................................ 322 Control Card Plugs.......................................................... 322 Brush Wear Indicators................................................... 323 Theory of Operation............................................................. 324 Electronic Speed Controls................................................... 324 Silicon Controlled Rectifier (SCR)...................................... 324 Motor Circuit That Operates With Pulses................................. 325 Traction Circuit........................................................ 327 Hydraulic Pump Motor.................................................... 327 SCR 1 OFF Circuit....................................................... 327 SCR 1 OFF Operation................................................. 328 Induction Current from Motor................................................ 330 Control Cards............................................................... 331 Pulse Monitor Trip (PMT) (Traction Circuit Only)........................ 331 SRO Circuit (Traction Circuit Only)..................................... 331 Sequence of Operation....................................................... 332 Control Card Adjustments (Traction Circuit)............................. 333 Accelerator Control..................................................... 336 SCR Control (Hydraulic Pump Motor).......................................... 336 Contactors.................................................................. 337 Circuit Protection.......................................................... 337 Traction Circuit Fuse................................................... 337 Current Limit........................................................... 337 Thermal Protection...................................................... 338 Suppressors............................................................. 338 Truck Management Module (TMM1).............................................. 338 Display Panels.............................................................. 339 Display Panel........................................................... 339 Basic Display........................................................... 339 Early Display Panel................................................. 340 Later Display Panel................................................. 341 Performance Display..................................................... 342 Brush Wear Indicators................................................... 345 tables.............................................................................. 221 Table 1. Terminal and Plug Wire Connections for Control Card ZY,................ 234 Table 2. Terminal and Plug Wire Connections for Control Card ZH,................ 236 Table 3. Terminal and Plug Wire Connections for Control Card ZH,................ 238 Table 4. Terminal and Plug Wire Connections for Controller with ................ 240 Table 5. Status Codes List...................................................... 259 Table 6. Register Map for Control Cards ZH and ZY (Traction).................... 261 Table 7. Register Map for Control Card ZP (Hydraulic Pump)...................... 266 Table 8. Terminal and Plug Wire Connections for TMM1 Module..................... 339 897640-2200SRM0560-(06-2004)-US-EN...................................................... 349 toc................................................................................. 349 Electrical System............................................................... 349 Safety Precautions Maintenance and Repair....................................... 350 General......................................................................... 355 Description..................................................................... 356 ZX Series Display Panels.................................................... 356 Display Panel........................................................... 356 Basic Display Panels.................................................... 356 Early Display Panel................................................. 356 Later Display Panel................................................. 356 Performance Display..................................................... 358 Brush Wear Indicators................................................... 362 SEM Display Panels - Features............................................... 362 Descriptions of Common Features......................................... 363 LED Symbol Indicators - SEM......................................... 363 LCD Screen.......................................................... 363 Battery Discharge Indicator (BDI)................................... 363 Service Reminder.................................................... 364 Status Codes........................................................ 364 Hourmeter........................................................... 364 Additional Features of Premium Display Panel............................ 364 Descriptions of Additional Features..................................... 364 LCD Screen.......................................................... 364 Operator Passwords.................................................. 364 Daily Checklist and Service Items................................... 365 Performance Modes................................................... 365 Status Code Lists................................................... 365 Adjustment of BDI................................................... 365 SEM Display Panel Indicators................................................ 365 All Indicator Symbols................................................... 365 Hourmeter Indicator Symbol.............................................. 366 Wrench Symbol........................................................... 366 Battery Symbol.......................................................... 366 Battery Discharge Indicator (BDI)....................................... 366 Brake Fluid Too Low Symbol.............................................. 366 Parking Brake Symbol.................................................... 366 Fasten Seat Belt Symbol................................................. 366 LCD Screen (Standard Display Panel)..................................... 366 Additional Components of Premium Display Panel.............................. 366 Alpha Numerical Screen.................................................. 366 STAR Push Button........................................................ 367 Push Buttons ##1 Through ##5 - SEM...................................... 367 Other Control Components.................................................... 367 Display Panel Components Replacement............................................ 368 ZX Panel Replacement........................................................ 368 Display Panel Assembly...................................................... 368 Key Switch, Replace......................................................... 369 Indicator LEDs.............................................................. 369 Battery Indicators.......................................................... 369 Digital Display (Performance Display Panel Only)............................ 369 Status Code or Performance Level Switches and Indicator LEDs (Pe............ 369 Basic Display Panel, Replace Parts.......................................... 369 Performance Display Panel, Replace Parts.................................... 371 SEM Display Panel Replacement................................................... 372 Motor Controller (SR or SP) Replacement......................................... 374 Remove...................................................................... 374 Install..................................................................... 374 Control Components Replacement.................................................. 375 Start Switch, Replace....................................................... 375 Brake Light Switch, Replace................................................. 375 Seat Switch, Replace........................................................ 376 External Seat Switch, Adjust................................................ 377 Switch for Optional Seat Brake, Replace..................................... 377 Parking Brake Switch, Replace............................................... 378 Direction Switches (MONOTROL Pedal), Replace................................ 379 Direction Control Switches (Steering Column), Replace....................... 380 Direction Control Switches, E70-120XL 3 (Steering Column)................... 381 Brake Fluid Switch, Replace................................................. 381 Brush Wear and Overtemperature Sensors...................................... 381 Rocker Switches for Lights.................................................. 381 Accelerator Position Sensor, Replace........................................ 382 On-Demand Steering Components............................................... 384 Lights, Converter, Relay, and Reverse Alarm................................. 386 Incandescent Brake, Tail, and Reverse Light Assembly, Replace........... 386 LED Brake, Tail, and Reverse Light Assembly, Replace.................... 386 Remove.............................................................. 386 Install............................................................. 386 Flashing Light Assembly, Replace........................................ 388 Front, Rear Driving Light, or Spot Light Assemblies, Replace............ 388 Operator Compartment Light Assembly, Replace............................ 390 Converter, Replace...................................................... 390 Relay, Replace.......................................................... 391 Reverse Alarm, Replace.................................................. 391 Horn and Horn Button........................................................ 391 Horn Switch and Cover................................................... 392 Hydraulic Pump Switches..................................................... 392 Control and Power Fuses Check................................................... 392 ZX Motor Controllers........................................................ 392 SEM Motor Controllers....................................................... 397 SEM Controller Field Diagnostic Procedure................................... 397 Armature FET Test....................................................... 397 Field FET Test.......................................................... 397 Brush Wear and Overtemperature Sensors Check - ZX Motor Controll................ 401 Thermal Sensors - SEM Motor Controllers Check................................... 402 Start Switch Adjustment......................................................... 403 Accelerator Potentiometer and Start Switch, E70-120XL, E70-120XL............ 404 E70-120XL............................................................... 404 E70-120XL 3............................................................. 404 Direction Switches (MONOTROL)............................................... 404 Brake Light Switch Adjustment................................................... 406 Seat Switch Check............................................................... 407 Optional Seat Brake Switch Adjustment........................................... 407 Parking Brake Switch Adjustment................................................. 408 Direction Switches Check........................................................ 408 Monotrol Pedal.............................................................. 408 Steering Column............................................................. 409 Hydraulic Pump Switch Adjustment................................................ 409 MONOTROL or Accelerator Pedal Adjustment........................................ 409 Accelerator Position Sensor Adjustment.......................................... 410 897641-8000SRM0561-(08-2003)-US......................................................... 415 toc................................................................................. 415 Capacities and Specifications................................................... 415 Safety Precautions Maintenance and Repair....................................... 416 Counterweights.................................................................. 419 Hydraulic System................................................................ 419 Wheels and Tires................................................................ 420 Battery Specifications.......................................................... 421 E2.00-3.20XM (E45-65XM, E45-65XM 2, N30XMH, N30XMH 2 )...................... 421 J2.00-3.20XM (J40-65XM, J40-65XM 2 )........................................ 422 Capacities...................................................................... 423 Movement Rates (Maximum) for Tilt Cylinders..................................... 423 Mast Speeds..................................................................... 424 E45-65XM Mast Speeds (36 or 48 Volt) Americas............................... 424 E40-65XM, E40-65XM 2, N30XMH 2 Mast Speeds (36 or 48 Volt) Ameri............ 430 E2.00-3.20XM Mast Speeds (72 or 80 Volt) Europe............................. 435 E2.00-3.20XM, E2.00-3.20XM 2 Mast Speeds (72 or 80 Volt) Europe............. 441 J40-65XM Mast Speeds (36 or 48 Volt) Americas............................... 444 J40-65XM, J40-65XM 2 Mast Speeds (36 or 48 Volt) Americas................... 448 J2.00-3.20XM Mast Speeds (72 or 80 Volt) Europe............................. 451 Torque Specifications........................................................... 459 Frame....................................................................... 459 Drive Axle, Speed Reducer, and Differential E.200-3.20XM (E45-65............ 459 Drive Axle, Speed Reducer, and Differential J2.00-3.20XM (J40-65............ 459 Steering Axle E2.00-3.20XM (E45-65XM, E45-65XM 2 and N30XMH, N30............ 460 Steering Axle J2.00-3.20XM (J40-65XM, J40-65XM 2 ).......................... 460 Masts....................................................................... 460 Seat Brake.................................................................. 460 Adhesives and Sealants.......................................................... 461 897781-8000SRM0589-(04-2006)-US-EN...................................................... 465 toc................................................................................. 465 Diagrams........................................................................ 465 Safety Precautions Maintenance and Repair....................................... 466 tables.............................................................................. 465 Table 1. Terminal and Plug Wire Connections for Control Card JH................. 498 Table 2. Terminal and Plug Wire Connections for Hydraulic Pump C................ 500 Table 3. Terminal and Plug Wire Connections for Control Card JH................. 501 Table 4. Terminal and Plug Wire Connections for TMM1 Module..................... 503 Table 5. Terminal and Plug Wire Connections for Control Card JY................. 504 1459370-1600SRM0720-(11-2006)-US-EN..................................................... 515 toc................................................................................. 515 Steering Housing and Control Unit............................................... 515 Safety Precautions Maintenance and Repair....................................... 516 General......................................................................... 519 Description..................................................................... 519 Operation....................................................................... 520 Steering Wheel and Column Assembly Repair....................................... 522 Assembly Components, Remove................................................. 522 Steering Control Unit, Disassemble.......................................... 525 Steering Control Unit, Clean................................................ 527 Steering Control Unit, Assemble............................................. 527 Assembly Components, Install................................................ 529 System Air Removal.............................................................. 530 Troubleshooting................................................................. 531 1463732-2200SRM0724-(09-2003)-US........................................................ 535 toc................................................................................. 535 SR/SP Transistor Motor Controllers.............................................. 535 Safety Precautions Maintenance and Repair....................................... 536 Description..................................................................... 541 General..................................................................... 541 Model Number Data for SR/SP Transistor Motor Controllers.................... 542 Motor Controller Checks and Adjustments......................................... 545 Checks and Adjustments Using Handset............................................ 545 General..................................................................... 545 Connect Handset............................................................. 546 Start Sequence.............................................................. 546 Check or Delete Stored Status Codes......................................... 547 Returning Lift Truck to Normal Operation.................................... 549 Workbench Checks and Adjustments............................................ 549 How to Check and Adjust Registers........................................... 551 Function Parameters Adjustments................................................. 552 General..................................................................... 552 Function Numbers............................................................ 552 When Handset is Connected to Motor Controller in Lift Truck................. 552 Function Numbers 1 through 15........................................... 553 Function Numbers 16 through 30.......................................... 553 Function Numbers 48 through 63.......................................... 553 Function Number Descriptions.................................................... 554 Traction Motor Controller (Label Letter - SR)................................... 554 Function Number 01 AUTO REGEN ENABLE SPEED.................................. 554 Function Number 02 CREEP SPEED.............................................. 555 Function Number 03 CONTROLLED ACCELERATION.................................. 555 Function Number 04 ARMATURE CURRENT LIMIT................................... 555 Function Number 05 REGEN RAMP RATE.......................................... 555 Function Number 06 FIELD WEAKENING (FW) RATIO............................... 555 Function Number 07 MINIMUM FIELD CURRENT.................................... 555 Function Number 08 MAXIMUM FIELD CURRENT.................................... 555 Function Number 09 REGENERATIVE BRAKING CURRENT LIMIT (C/L)................. 556 Function Number 10 FIELD CURRENT FOR REGENERATIVE BRAKING................... 556 Function Number 12 MAXIMUM ARMATURE % ON TIME (Travel Speed Limi............ 556 Function Number 13 SPEED LIMIT 3............................................ 556 Function Number 14 INTERNAL RESISTANCE COMPENSATION......................... 556 Function Number 15 BATTERY VOLTAGE SELECTION................................ 557 Function Number 16 STALL TRIP POINT % ON TIME............................... 557 Function Number 17 CONTROL TYPE SELECTION................................... 557 Function Number 18 STEERING PUMP TIME DELAY................................. 558 Function Number 19 MAINTENANCE CODE TENS AND UNITS.......................... 558 Function Number 20 MAINTENANCE CODE THOUSANDS AND HUNDREDS.................. 558 Function Number 21 AUTO REGEN BRAKING CURRENT LIMIT......................... 558 Function Number 23 FOR SPECIAL FUNCTIONS.................................... 558 Function Number 24 FIELD WEAKENING START.................................... 558 Function Number 25 MONITOR.................................................. 558 Function Number 26 BASE RATIO............................................... 559 Function Number 28 STORED STATUS CODE COUNT POINTER......................... 559 Functions with Premium Display Panel Only................................... 559 Function Number 48 MODE 1 - CONTROLLED ACCELERATION..................... 559 Function Number 49 MODE 1 FIELD WEAKENING (FW) START.................... 560 Function Number 50 MODE 1 - FIELD WEAKENING (FW) RATIO.................. 560 Function 51 MODE 1 - MAXIMUM ARMATURE % ON TIME (MODE 1 - TRAVEL........ 560 Function 52 MODE 2 - CONTROLLED ACCELERATION............................ 560 Function Number 53 MODE 2 - FIELD WEAKENING (FW) START.................. 560 Function Number 54 MODE 2 - FIELD WEAKENING (FW) RATIO.................. 560 Function Number 55 MODE 2 - MAXIMUM ARMATURE % ON TIME (MODE 2 -........ 561 Function Number 56 MODE 3 - CONTROLLED ACCELERATION..................... 561 Function Number 57 MODE 3 - FIELD WEAKENING (FW) START.................. 561 Function Number 58 MODE 3 - FIELD WEAKENING (FW) RATIO.................. 561 Function Number 59 MODE 3 - MAXIMUM ARMATURE % ON TIME (MODE 3 -........ 561 Function Number 60 MODE 4 - CONTROLLED ACCELERATION..................... 561 Function Number 61 MODE 4 - FIELD WEAKENING (FW) START.................. 561 Function Number 62 MODE 4 - FIELD WEAKENING (FW) RATIO.................. 561 Function Number 63 MODE 4 - MAXIMUM ARMATURE % ON TIME (MODE 4 -........ 562 Pump Motor Controller (Label Letter - SP)....................................... 562 Function Number 01 STORED STATUS CODE....................................... 562 Function Number 02 INTERNAL RESISTANCE COMPENSATION START................... 562 Function Number 03 CONTROLLED ACCELERATION.................................. 562 Function Number 04 CURRENT LIMIT............................................ 562 Function Number 07 INTERNAL RESISTANCE COMPENSATION RATE.................... 563 Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and S............ 563 Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lif............ 563 Function Number 13 SPEED LIMIT 3 (SL3) Fast Lift............................ 563 Function Number 16 SPEED/TORQUE COMPENSATION................................ 563 Function Number 17 CONTROL TYPE SELECTION................................... 564 Function Numbers 18 through 27 TEMPORARY DATA REGISTERS..................... 564 Function Number 28 STORED STATUS CODE COUNT POINTER......................... 564 Functions with Premium Display Panel Only................................... 564 Function Number 48 MODE 1 - CONTROLLED ACCELERATION..................... 564 Function Number 49 MODE 1 - SPEED LIMIT 2............................... 564 Function Number 50 MODE 1 - SPEED LIMIT 3............................... 565 Function Number 52 MODE 2 - CONTROLLED ACCELERATION..................... 565 Function Number 53 MODE 2 - SPEED LIMIT 2............................... 565 Function Number 54 MODE 2 - SPEED LIMIT 3............................... 565 Function Number 56 MODE 3 - CONTROLLED ACCELERATION..................... 565 Function Number 57 MODE 3 - SPEED LIMIT 2............................... 565 Function Number 58 MODE 3 - SPEED LIMIT 3............................... 565 Function Number 60 MODE 4 - CONTROLLED ACCELERATION..................... 565 Function Number 61 MODE 4 - SPEED LIMIT 2............................... 566 Function Number 62 MODE 4 - SPEED LIMIT 3............................... 566 Troubleshooting................................................................. 570 General..................................................................... 570 Status Codes................................................................ 570 SR (SEM) and SP Status Code Charts.............................................. 573 SR/SP Transistor Motor Controller Repair........................................ 608 General..................................................................... 608 General Maintenance Instructions............................................ 610 Special Precautions..................................................... 610 Fuses....................................................................... 611 Contactors.................................................................. 611 Repair.................................................................. 612 Contactor Driver Module..................................................... 612 Contactor Driver, Replace............................................... 612 Motor Controller Plug....................................................... 615 Brush Wear Indicators....................................................... 619 Thermal Sensors............................................................. 619 Motor Controller, Replace................................................... 619 Theory of Operation............................................................. 620 General..................................................................... 620 SEM System Description...................................................... 620 SEM System Operation (SR Motor Controller).................................. 621 Reverse Circuit......................................................... 621 Performance and Efficiency.............................................. 622 Field Weakening......................................................... 622 Regenerative Braking.................................................... 623 SEM System Operation (SP Motor Controller).................................. 623 Creep Speed............................................................. 623 Controlled Acceleration................................................. 623 Current Limit (CL)...................................................... 623 Braking..................................................................... 623 Regenerative Braking to Zero Speed...................................... 623 Pedal Position Braking.................................................. 624 Auto Braking............................................................ 624 Auxiliary Speed Control..................................................... 624 Field Weakening......................................................... 624 Speed Limits............................................................ 624 Ramp Operation.............................................................. 624 Ramp Start.............................................................. 624 Anti-rollback........................................................... 624 Steer Pump Contactor Time Delay............................................. 624 Coil Drivers and Internal Coil Suppression.................................. 625 System Protective Override.................................................. 625 Static Return to Off (SRO).............................................. 625 Accelerator Volts Hold Off.............................................. 625 Pulse Monitor Trip (PMT)................................................ 625 Thermal Protector (TP).................................................. 625 Low Voltage............................................................. 625 SP Pump Motor Controllers................................................... 625 Contactor Driver Module..................................................... 626 Diagnostics................................................................. 626 Systems Diagnostics..................................................... 626 Standard Status Codes................................................... 626 Stored Status Codes..................................................... 626 Hourmeter Readings...................................................... 627 Maintenance Management Capability....................................... 627 tables.............................................................................. 535 Table 1. List of Status Codes................................................... 548 Table 2. Speed/Torque Compensation.............................................. 563 Table 3. Function Map for Motor Controllers SR (Traction)....................... 566 Table 4. Function Map for Motor Controller SP (Lift Pump Motor)................. 568 Table 5. List of Status Codes................................................... 571 Table 6. Large (P) Plug (23-Pin) Connections/Descriptions for Mo................ 615 Table 7. Small Plug (12-Pin) Connections/Descriptions for Motor ................ 616 1463738-2200SRM0725-(01-1999)-US-EN..................................................... 631 SEM DISPLAY PANEL................................................................... 631 GENERAL......................................................................... 631 SEM DISPLAY PANEL FEATURES...................................................... 631 Description Of Common Features.............................................. 631 LED SYMBOL INDICATORS....................................................... 631 LED SCREEN ................................................................. 631 BATTERY DISCHARGE INDICATOR (BDI)........................................... 631 SERVCE REMINDER............................................................. 632 STATUS CODES................................................................ 632 HOURMETER................................................................... 632 Additional Features Of Premium Display Panel................................ 632 Descriptions Of Additional Features (Available With The Premium Display).... 632 LCD SCREEN.................................................................. 632 OPERATOR PASSWORDS.......................................................... 632 DAILY CHECK LIST AND SERVICE ITEMS.......................................... 633 PERFORMANCE MODES........................................................... 633 STATUS CODES LIST........................................................... 633 ADJUSTMENT OF BDI........................................................... 634 SEM DISPLAY PANEL INDICATORS.................................................... 634 All Indicator Symbols....................................................... 634 Hourmeter Indicator Symbol.................................................. 635 Wrench Indicator Symbol..................................................... 635 Battery Indicator Symbol.................................................... 635 Battery State-Of-Charge (BDI)............................................... 635 Brake Fluid Too Low Symbol.................................................. 635 Parking Brake Symbol........................................................ 635 Fasten Seat Belt Symbol..................................................... 635 LCD Screen (Standard Display Panel)......................................... 635 ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL.............................. 635 Alpha Numeric Screen........................................................ 635 "STAR" Push Button.......................................................... 636 Push Buttons #1 Through #5.................................................. 636 ADJUSTMENTS WITH A COMPUTER..................................................... 637 COMPUTER SYSTEM............................................................. 637 Connect A PC To The SEM Display Panel....................................... 637 ITW SWITCHES SOFTWARE PROGRAM (For SEM Display Panel)....................... 638 Description............................................................. 638 Where To Get Help....................................................... 638 Hardware And Software Requirements...................................... 638 How To Start The ITW SWITCHES Program................................... 639 Menus................................................................... 639 Create A Setup File..................................................... 647 REPLACEMENT..................................................................... 667 GENERAL..................................................................... 667 SEM DISPLAY PANEL........................................................... 667 Removal And Replacement .................................................... 667 1463744-2200SRM0739-(04-2005)-US-EN..................................................... 670 toc................................................................................. 670 Transistor Motor Controllers.................................................... 670 Safety Precautions Maintenance and Repair....................................... 671 General......................................................................... 674 Function Numbers............................................................ 674 Motor Controller Checks and Adjustments......................................... 675 Parameter Tables............................................................ 675 tables.............................................................................. 670 Table 1. SR (SEM) Register Parameters for Traction Motor Control................ 675 Table 2. SR (SEM) Register Parameters for Traction Motor Control................ 679 Table 3. SP Register Parameters for Pump Motor Controller - E1.5................ 682 Table 4. SR (SEM) Register Parameters for Traction Motor Control................ 686 Table 5. SR (SEM) Register Parameters for Traction Motor Control................ 690 Table 6. SR (SEM) Register Parameters for Traction Motor Control................ 693 Table 7. SR (SEM) Register Parameters for Traction Motor Control................ 697 Table 8. SP Register Parameters for Pump Motor Controller - E45-................ 700 Table 9. SP Register Parameters for Pump Motor Controller - E2.0................ 704 Table 10. SR (SEM) Register Parameters for Traction Motor Contro................ 708 Table 11. SR (SEM) Register Parameters for Traction Motor Contro................ 711 Table 12. SR (SEM) Register Parameters for Traction Motor Contro................ 714 Table 13. SP Register Parameters for Pump Motor Controller - J40................ 717 Table 14. SP Register Parameters for Pump Motor Controller - J2................. 720 Table 15. SR (SEM) Register Parameters for Traction Motor Contro................ 724 Table 16. SR (SEM) Register Parameters for Traction Motor Contro................ 728 Table 17. SP Register Parameters for Pump Motor Controller - N30................ 732 1463744-2200SRM0739-(08-2003)-US........................................................ 738 toc................................................................................. 738 Transistor Motor Controllers.................................................... 738 Safety Precautions Maintenance and Repair....................................... 739 General......................................................................... 742 Function Numbers............................................................ 742 Motor Controller Checks and Adjustments......................................... 743 Parameter Tables............................................................ 743 tables.............................................................................. 738 Table 1. SR (SEM) Register Parameters for Traction Motor Control................ 743 Table 2. SR (SEM) Register Parameters for Traction Motor Control................ 747 Table 3. SP Register Parameters for Pump Motor Controller - E1.5................ 750 Table 4. SR (SEM) Register Parameters for Traction Motor Control................ 753 Table 5. SR (SEM) Register Parameters for Traction Motor Control................ 757 Table 6. SR (SEM) Register Parameters for Traction Motor Control................ 760 Table 7. SR (SEM) Register Parameters for Traction Motor Control................ 764 Table 8. SP Register Parameters for Pump Motor Controller - E45-................ 767 Table 9. SP Register Parameters for Pump Motor Controller - E2.0................ 771 Table 10. SR (SEM) Register Parameters for Traction Motor Contro................ 774 Table 11. SR (SEM) Register Parameters for Traction Motor Contro................ 777 Table 12. SR (SEM) Register Parameters for Traction Motor Contro................ 780 Table 13. SP Register Parameters for Pump Motor Controller - J40................ 783 Table 14. SP Register Parameters for Pump Motor Controller - J2................. 786 Table 15. SR (SEM) Register Parameters for Traction Motor Contro................ 789 Table 16. SR (SEM) Register Parameters for Traction Motor Contro................ 793 Table 17. SP Register Parameters for Pump Motor Controller - N30................ 797 1464329-8000SRM0742-(06-2004)-US-EN..................................................... 802 toc................................................................................. 802 Electrical Diagrams............................................................. 802 Safety Precautions Maintenance and Repair....................................... 803 1494238-2200SRM0942-(06-2002)-US........................................................ 872 toc................................................................................. 872 Display Panel for SEM Controls.................................................. 872 Safety Precautions Maintenance and Repair....................................... 873 General......................................................................... 876 SEM Display Panel Features...................................................... 876 Descriptions of Common Features............................................. 876 LED Symbol Indicators................................................... 876 LCD Screen.............................................................. 876 Battery Discharge Indicator (BDI)....................................... 876 Service Reminder........................................................ 877 Status Codes............................................................ 877 Hourmeter............................................................... 877 Additional Features of Premium Display Panel................................ 877 Descriptions of Additional Features (Available with Premium Disp............ 877 LCD Screen.............................................................. 877 Operator Passwords...................................................... 877 Daily Check List and Service Items...................................... 878 Performance Modes....................................................... 878 Status Code Lists....................................................... 878 Adjustment of BDI....................................................... 878 SEM Display Panel Indicators.................................................... 878 All Indicator Symbols....................................................... 878 Hourmeter Indicator Symbol.................................................. 879 Wrench Indicator Symbol..................................................... 879 Battery Indicator Symbol.................................................... 879 Battery State-of-Charge (BDI)............................................... 879 Brake Fluid Too Low Symbol.................................................. 879 Parking Brake Symbol........................................................ 879 Fasten Seat Belt Symbol..................................................... 880 LCD Screen (Standard Display Panel)......................................... 880 Additional Components of Premium Display Panel.................................. 881 Alphanumeric Screen......................................................... 881 STAR Push Button............................................................ 881 Push Buttons 1 Through 5.................................................... 881 Adjustments With a Computer..................................................... 881 Computer System............................................................. 881 Connect PC to SEM Display Panel......................................... 882 ITW Switches Windows Software Program (for SEM Display Panel)............... 882 Description............................................................. 882 Where to Get Help....................................................... 883 Hardware and Software Requirements...................................... 883 Install................................................................. 883 How to Start ITW SWITCHES Program....................................... 883 Menus................................................................... 887 Sample Sessions......................................................... 895 Replacement..................................................................... 918 SEM Display Panel........................................................... 918 Remove and Replace...................................................... 918 tables.............................................................................. 872 Table 1. Adapter Pins (DB25F to DB9)............................................ 881 1494238-2200SRM0942-(06-2002)-US-EN..................................................... 924 toc................................................................................. 924 Display Panel for SEM Controls.................................................. 924 Safety Precautions Maintenance and Repair....................................... 925 General......................................................................... 928 SEM Display Panel Features...................................................... 928 Descriptions of Common Features............................................. 928 LED Symbol Indicators................................................... 928 LCD Screen.............................................................. 928 Battery Discharge Indicator (BDI)....................................... 928 Service Reminder........................................................ 929 Status Codes............................................................ 929 Hourmeter............................................................... 929 Additional Features of Premium Display Panel................................ 929 Descriptions of Additional Features (Available with Premium Disp............ 929 LCD Screen.............................................................. 929 Operator Passwords...................................................... 929 Daily Check List and Service Items...................................... 930 Performance Modes....................................................... 930 Status Code Lists....................................................... 930 Adjustment of BDI....................................................... 930 SEM Display Panel Indicators.................................................... 930 All Indicator Symbols....................................................... 930 Hourmeter Indicator Symbol.................................................. 931 Wrench Indicator Symbol..................................................... 931 Battery Indicator Symbol.................................................... 931 Battery State-of-Charge (BDI)............................................... 931 Brake Fluid Too Low Symbol.................................................. 931 Parking Brake Symbol........................................................ 931 Fasten Seat Belt Symbol..................................................... 932 LCD Screen (Standard Display Panel)......................................... 932 Additional Components of Premium Display Panel.................................. 933 Alphanumeric Screen......................................................... 933 STAR Push Button............................................................ 933 Push Buttons 1 Through 5.................................................... 933 Adjustments With a Computer..................................................... 933 Computer System............................................................. 933 Connect PC to SEM Display Panel......................................... 934 ITW Switches Windows Software Program (for SEM Display Panel)............... 934 Description............................................................. 934 Where to Get Help....................................................... 935 Hardware and Software Requirements...................................... 935 Install................................................................. 935 How to Start ITW SWITCHES Program....................................... 935 Menus................................................................... 939 Sample Sessions......................................................... 947 Replacement..................................................................... 970 SEM Display Panel........................................................... 970 Remove and Replace...................................................... 970 tables.............................................................................. 924 Table 1. Adapter Pins (DB25F to DB9)............................................ 933 1494933-2200SRM0947-(08-2003)-US........................................................ 976 toc................................................................................. 976 Troubleshooting and Adjustments With a Computer................................. 976 Safety Precautions Maintenance and Repair....................................... 977 Computer System................................................................. 980 Connect a PC to a Control Card.............................................. 981 Installation................................................................ 982 HYTECHβ’ Windows Software Program................................................ 982 How to Start the Program.................................................... 982 DEMO Mode................................................................... 983 Selecting the Communications Port........................................... 985 Verification of Controller and Lift Truck................................... 986 Select Lift Truck Series.................................................... 988 Controller Card Register Parameter List..................................... 989 How to Change a Parameter................................................... 990 How to Save a Changed Parameter File........................................ 991 How to Load a Saved Parameter File.......................................... 992 How to Show and Remove Saved Parameter Files................................ 993 How to Return to Factory Default Settings................................... 994 How to Save Changes to Control Card......................................... 995 How to View Status Codes.................................................... 996 Saving Status Codes......................................................... 997 How to Show and Remove Saved Status Code Files.............................. 999 Closing and Clearing Status Code List....................................... 999 How to View Saved Register Data and Saved Status Data.......................1000 How to Save Register Data and Status Code Data In .RTF and .TXT ............1002 GE Sentryβ’ Software Program.....................................................1003 Installation................................................................1003 Description.................................................................1003 How to Start GE SENTRY Program..............................................1003 How to Reset MIN and MAX Display............................................1008 Graphing Mode...............................................................1009 How to Exit GE SENTRY Program...............................................1010 tables.............................................................................. 976 Table 1. Cable Connections - Computer to Control................................ 980 Table 2. Adapter Pins (DB25F to DB9)............................................ 980 Table 3. Plug-Z Connection...................................................... 981 1494933-2200SRM0947-(08-2003)-US-EN.....................................................1014 toc.................................................................................1014 Troubleshooting and Adjustments With a Computer.................................1014 Safety Precautions Maintenance and Repair.......................................1015 Computer System.................................................................1018 Connect a PC to a Control Card..............................................1019 Installation................................................................1020 HYTECHβ’ Windows Software Program................................................1020 How to Start the Program....................................................1020 DEMO Mode...................................................................1021 Selecting the Communications Port...........................................1023 Verification of Controller and Lift Truck...................................1024 Select Lift Truck Series....................................................1026 Controller Card Register Parameter List.....................................1027 How to Change a Parameter...................................................1028 How to Save a Changed Parameter File........................................1029 How to Load a Saved Parameter File..........................................1030 How to Show and Remove Saved Parameter Files................................1031 How to Return to Factory Default Settings...................................1032 How to Save Changes to Control Card.........................................1033 How to View Status Codes....................................................1034 Saving Status Codes.........................................................1035 How to Show and Remove Saved Status Code Files..............................1037 Closing and Clearing Status Code List.......................................1037 How to View Saved Register Data and Saved Status Data.......................1038 How to Save Register Data and Status Code Data In .RTF and .TXT ............1040 GE Sentryβ’ Software Program.....................................................1041 Installation................................................................1041 Description.................................................................1041 How to Start GE SENTRY Program..............................................1041 How to Reset MIN and MAX Display............................................1046 Graphing Mode...............................................................1047 How to Exit GE SENTRY Program...............................................1048 tables..............................................................................1014 Table 1. Cable Connections - Computer to Control................................1018 Table 2. Adapter Pins (DB25F to DB9)............................................1018 Table 3. Plug-Z Connection......................................................1019 2200288.................................................................................1052 INTRODUCTION........................................................................1052 GENERAL.........................................................................1052 DESCRIPTION.....................................................................1052 OPERATION.......................................................................1052 REPAIRS.............................................................................1053 STEERING WHEEL AND COLUMN ASSEMBLY..............................................1053 Removal of the Assembly Components..........................................1057 Disassembly of the Steering Control Unit....................................1058 Cleaning of the Steering Control Unit.......................................1058 Assembly of the Steering Control Unit.......................................1058 Installation of the Steering Control Unit...................................1058 Installation of the Assembly Components.....................................1058 CHECKS AND ADJUSTMENTS..............................................................1066 REMOVE AIR FROM THE SYSTEM......................................................1066 TROUBLESHOOTING.....................................................................1066
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