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Hyster F108V (E60XM2-33) Service Manual – PDF DOWNLOAD
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Description
Hyster F108V (E60XM2-33) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F108V (E60XM2-33) 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 F108V (E60XM2-33) Service Manual – PDF DOWNLOAD
4 Stage Mast (1).................................................................... 1 toc............................................................................. 1 Four-Stage Mast............................................................. 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Description................................................................. 5 Carriages............................................................... 5 Mast Mounts............................................................. 6 Mast.................................................................... 6 Description......................................................... 6 Operation........................................................... 7 Forks Repair................................................................ 10 Remove.................................................................. 10 Install................................................................. 10 Safety Procedures When Working Near Mast.................................... 12 Carriage Repair............................................................. 15 Remove.................................................................. 15 Standard Carriage................................................... 15 Sideshift Carriage.................................................. 15 Repairs................................................................. 16 Install................................................................. 17 Standard Carriage................................................... 17 Sideshift Carriage.................................................. 17 Mast Repair................................................................. 18 Remove.................................................................. 18 Disassemble............................................................. 18 Clean and Inspect....................................................... 19 Assemble................................................................ 20 Install................................................................. 23 Lift Cylinders Repair....................................................... 26 Remove.................................................................. 26 Main Lift Cylinders................................................. 26 Free-Lift Cylinders................................................. 26 Disassemble............................................................. 28 Assemble................................................................ 28 Install................................................................. 30 Main Lift Cylinder.................................................. 30 Free-Lift Cylinder.................................................. 31 Header Hose Arrangements.................................................... 32 Header Hoses, Install................................................... 32 Lift and Tilt System Leaks Check............................................ 39 Lift Cylinders Leaks Check.............................................. 39 Tilt Cylinders Leaks Check.............................................. 39 Tilt Cylinders Adjustment................................................... 40 Lift Chain Adjustments...................................................... 40 Mast Adjustments............................................................ 42 Carriage Adjustments........................................................ 44 Troubleshooting............................................................. 45 tables.......................................................................... 1 Table 1. Standard Four-Stage Hose Dimensions................................ 38 Table 2. Hook type Carriage Chain Adjustment................................ 41 Table 3. Pin-Type Carriage Chain Adjustment................................. 41 4 Stage Mast........................................................................ 49 toc............................................................................. 49 Four-Stage Mast............................................................. 49 Safety Precautions Maintenance and Repair................................... 50 General..................................................................... 53 Description................................................................. 53 Carriages............................................................... 53 Mast Mounts............................................................. 54 Mast.................................................................... 54 Description......................................................... 54 Operation........................................................... 55 Forks Repair................................................................ 58 Remove.................................................................. 58 Install................................................................. 58 Safety Procedures When Working Near Mast.................................... 60 Carriage Repair............................................................. 63 Remove.................................................................. 63 Standard Carriage................................................... 63 Sideshift Carriage.................................................. 63 Repairs................................................................. 64 Install................................................................. 65 Standard Carriage................................................... 65 Sideshift Carriage.................................................. 65 Mast Repair................................................................. 66 Remove.................................................................. 66 Disassemble............................................................. 66 Clean and Inspect....................................................... 67 Assemble................................................................ 68 Install................................................................. 71 Lift Cylinders Repair....................................................... 74 Remove.................................................................. 74 Main Lift Cylinders................................................. 74 Free-Lift Cylinders................................................. 74 Disassemble............................................................. 76 Assemble................................................................ 76 Install................................................................. 78 Main Lift Cylinder.................................................. 78 Free-Lift Cylinder.................................................. 79 Header Hose Arrangements.................................................... 80 Header Hoses, Install................................................... 80 Lift and Tilt System Leaks Check............................................ 87 Lift Cylinders Leaks Check.............................................. 87 Tilt Cylinders Leaks Check.............................................. 87 Tilt Cylinders Adjustment................................................... 88 Lift Chain Adjustments...................................................... 88 Mast Adjustments............................................................ 90 Carriage Adjustments........................................................ 92 Troubleshooting............................................................. 93 tables.......................................................................... 49 Table 1. Standard Four-Stage Hose Dimensions................................ 86 Table 2. Hook type Carriage Chain Adjustment................................ 89 Table 3. Pin-Type Carriage Chain Adjustment................................. 89 100ZX Programming (1)............................................................... 97 toc............................................................................. 97 EV-100ZX™ SCR Motor Controller.............................................. 97 Safety Precautions Maintenance and Repair................................... 98 Register Parameters......................................................... 101 General................................................................. 101 Function Numbers........................................................ 101 Control Card Checks and Adjustments......................................... 102 Register Parameter Tables................................................... 102 tables.......................................................................... 97 Table 1. EV-100ZX Parameters - E40-65XM, J40-60XM, and N30XMH (3............ 103 Table 2. EV-100ZX Parameters - E45-65XM, and N30XMH (36 to 48V) ............ 107 Table 3. EV-100ZX Parameters - E2.00-3.20XM, and J2.00-3.20XM (7............ 111 Table 4. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V) (Tractio............ 115 Table 5. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V) (Low Ene............ 119 Table 6. EV-100ZX Parameters - E40-65XM, J40-60XM, E70-120XL, an............ 123 Table 7. EV-100ZX Parameters - E2.00-3.20XM, J2.00-3.20XM, and E............ 127 100ZX Programming................................................................... 133 toc............................................................................. 133 EV-100ZX™ SCR Motor Controller.............................................. 133 Safety Precautions Maintenance and Repair................................... 134 Register Parameters......................................................... 137 General................................................................. 137 Function Numbers........................................................ 137 Control Card Checks and Adjustments......................................... 138 Register Parameter Tables................................................... 138 tables.......................................................................... 133 Table 1. EV-100ZX Parameters - E40-65XM, J40-60XM, and N30XMH (3............ 139 Table 2. EV-100ZX Parameters - E45-65XM, and N30XMH (36 to 48V) ............ 143 Table 3. EV-100ZX Parameters - E2.00-3.20XM, and J2.00-3.20XM (7............ 147 Table 4. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V) (Tractio............ 151 Table 5. EV-100ZX Parameters - E2.00-3.20XM (72 to 80V) (Low Ene............ 155 Table 6. EV-100ZX Parameters - E40-65XM, J40-60XM, E70-120XL, an............ 159 Table 7. EV-100ZX Parameters - E2.00-3.20XM, J2.00-3.20XM, and E............ 163 Battery (1)......................................................................... 169 toc............................................................................. 169 Industrial Battery.......................................................... 169 Safety Precautions Maintenance and Repair................................... 170 General..................................................................... 173 Lead-Acid Batteries......................................................... 173 Specific Gravity............................................................ 174 Chemical Reaction in a Cell................................................. 174 Electrical Terms............................................................ 175 Battery Selection........................................................... 176 Battery Voltage............................................................. 177 Battery as a Counterweight.................................................. 177 Battery Ratings............................................................. 178 Kilowatt-Hours.......................................................... 178 Battery Maintenance......................................................... 178 Safety Procedures....................................................... 178 Maintenance Records..................................................... 179 New Battery............................................................. 179 Cleaning Battery........................................................ 179 Adding Water to Battery................................................. 181 Hydrometer.............................................................. 182 Battery Temperature..................................................... 182 Charging Battery........................................................ 183 Types of Battery Charges............................................ 184 Methods of Charging................................................. 185 Troubleshooting Charger............................................. 186 Knowing When Battery Is Fully Charged............................... 186 Where to Charge Batteries............................................... 186 Equipment Needed.................................................... 186 Battery Connectors...................................................... 187 Battery Care............................................................ 187 tables.......................................................................... 169 Table 1. Battery Capacity Terms............................................. 178 Battery............................................................................. 191 toc............................................................................. 191 Industrial Battery.......................................................... 191 Safety Precautions Maintenance and Repair................................... 192 General..................................................................... 195 Lead-Acid Batteries......................................................... 195 Specific Gravity............................................................ 196 Chemical Reaction in a Cell................................................. 196 Electrical Terms............................................................ 197 Battery Selection........................................................... 198 Battery Voltage............................................................. 199 Battery as a Counterweight.................................................. 199 Battery Ratings............................................................. 200 Kilowatt-Hours.......................................................... 200 Battery Maintenance......................................................... 200 Safety Procedures....................................................... 200 Maintenance Records..................................................... 201 New Battery............................................................. 201 Cleaning Battery........................................................ 201 Adding Water to Battery................................................. 203 Hydrometer.............................................................. 204 Battery Temperature..................................................... 204 Charging Battery........................................................ 205 Types of Battery Charges............................................ 206 Methods of Charging................................................. 207 Troubleshooting Charger............................................. 208 Knowing When Battery Is Fully Charged............................... 208 Where to Charge Batteries............................................... 208 Equipment Needed.................................................... 208 Battery Connectors...................................................... 209 Battery Care............................................................ 209 tables.......................................................................... 191 Table 1. Battery Capacity Terms............................................. 200 Brakes (1).......................................................................... 213 toc............................................................................. 213 Brake System................................................................ 213 Safety Precautions Maintenance and Repair................................... 214 General..................................................................... 217 Description and Operation................................................... 217 Service Brakes.......................................................... 217 Master Cylinder......................................................... 218 Parking Brake........................................................... 219 Service Brakes Repair....................................................... 219 Remove and Disassemble.................................................. 219 Clean................................................................... 223 Inspect................................................................. 223 Assemble and Install.................................................... 223 Adjust.................................................................. 226 Parking Brake Repair........................................................ 228 Remove and Disassemble.................................................. 228 Assemble and Install.................................................... 228 Adjust.................................................................. 229 Master Cylinder Repair...................................................... 233 Remove.................................................................. 233 Disassemble............................................................. 234 Clean and Inspect....................................................... 236 Assemble................................................................ 236 Install................................................................. 239 Seat Brake Assembly......................................................... 239 Seat Brake, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM, E........ 239 Brake Switch, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM,........ 239 Electric Seat Brake, Adjust for Lift Truck Model E2.00-3.20XM (E........ 240 Electric Seat Brake Adjustment With Handle For Lift truck Models........ 242 Remove.............................................................. 242 Clean............................................................... 242 Inspect............................................................. 242 Install............................................................. 244 Adjustments............................................................. 244 Solenoid Adjustment................................................. 244 Traction cutoff Switch Adjustment................................... 244 Cable Adjustment.................................................... 246 Service Brakes Adjustment................................................... 248 Brake Pedal Adjustment...................................................... 248 Master Cylinder Adjustment.................................................. 248 Brake System Air Removal.................................................... 248 Parking Brake Not Applied Switch Test....................................... 249 Torque Specifications....................................................... 249 Troubleshooting............................................................. 249 Brakes.............................................................................. 255 toc............................................................................. 255 Brake System................................................................ 255 Safety Precautions Maintenance and Repair................................... 256 General..................................................................... 259 Description and Operation................................................... 259 Service Brakes.......................................................... 259 Master Cylinder......................................................... 260 Parking Brake........................................................... 261 Service Brakes Repair....................................................... 261 Remove and Disassemble.................................................. 261 Clean................................................................... 265 Inspect................................................................. 265 Assemble and Install.................................................... 265 Adjust.................................................................. 268 Parking Brake Repair........................................................ 270 Remove and Disassemble.................................................. 270 Assemble and Install.................................................... 270 Adjust.................................................................. 271 Master Cylinder Repair...................................................... 275 Remove.................................................................. 275 Disassemble............................................................. 276 Clean and Inspect....................................................... 278 Assemble................................................................ 278 Install................................................................. 281 Seat Brake Assembly......................................................... 281 Seat Brake, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM, E........ 281 Brake Switch, Adjust - Lift Truck Models E2.00-3.20XM (E45-65XM,........ 281 Electric Seat Brake, Adjust for Lift Truck Model E2.00-3.20XM (E........ 282 Electric Seat Brake Adjustment With Handle For Lift truck Models........ 284 Remove.............................................................. 284 Clean............................................................... 284 Inspect............................................................. 284 Install............................................................. 286 Adjustments............................................................. 286 Solenoid Adjustment................................................. 286 Traction cutoff Switch Adjustment................................... 286 Cable Adjustment.................................................... 288 Service Brakes Adjustment................................................... 290 Brake Pedal Adjustment...................................................... 290 Master Cylinder Adjustment.................................................. 290 Brake System Air Removal.................................................... 290 Parking Brake Not Applied Switch Test....................................... 291 Torque Specifications....................................................... 291 Troubleshooting............................................................. 291 Dash (1)............................................................................ 297 toc............................................................................. 297 Mast........................................................................ 297 Safety Precautions Maintenance and Repair................................... 298 General..................................................................... 301 Description and Operation................................................... 301 Carriages............................................................... 301 Mast Mounts............................................................. 303 Two-Stage Mast, Limited Free-Lift (LFL)..................................... 305 Description and Operation............................................... 305 Two-Stage Mast, Full Free-Lift (FFL)........................................ 307 Description and Operation............................................... 307 Three-Stage Mast, Full Free-Lift (FFL)...................................... 309 Description and Operation............................................... 309 Four-Stage Mast............................................................. 312 Description and Operation............................................... 312 Cylinder Cushion During Lifting Sequence.................................... 315 Cylinder Cushion During Lowering Sequence................................... 316 Dash Cluster (1).................................................................... 319 toc............................................................................. 319 Instrument Cluster.......................................................... 319 Safety Precautions Maintenance and Repair................................... 320 General..................................................................... 323 Description................................................................. 323 Display Panels on Steering Column, Internal Combustion.................. 323 Display Panels on Steering Column, Electric Lift Trucks................. 328 Standard Display Panel.............................................. 328 Enhanced Display Panel.............................................. 329 Curtis 1215 Display Panel............................................... 333 Description and Features............................................ 333 Operation........................................................... 333 Cluster-Type Display Panel (Internal Combustion) Replacement................ 334 Remove and Disassemble.................................................. 334 Assemble and Install.................................................... 337 Cluster Display Panel (Electric Lift Truck) Replacement..................... 339 Display Panel Assembly, Replace......................................... 339 LED Indicators.......................................................... 339 Battery Indicators...................................................... 340 Digital Display (Enhanced Display Panel Only)........................... 340 Status Code or Performance Level Switches and LED indicators (En........ 340 Standard Display Panel Parts, Replace................................... 340 Enhanced Display Panel Parts, Replace................................... 341 Curtis 1215 Display Panel Replacement....................................... 341 Remove.................................................................. 341 Install................................................................. 341 tables.......................................................................... 319 Table 1. Instrument Cluster, Internal Combustion............................ 323 Dash Cluster........................................................................ 345 toc............................................................................. 345 Instrument Cluster.......................................................... 345 Safety Precautions Maintenance and Repair................................... 346 General..................................................................... 349 Description................................................................. 349 Display Panels on Steering Column, Internal Combustion.................. 349 Display Panels on Steering Column, Electric Lift Trucks................. 354 Standard Display Panel.............................................. 354 Enhanced Display Panel.............................................. 355 Curtis 1215 Display Panel............................................... 359 Description and Features............................................ 359 Operation........................................................... 359 Cluster-Type Display Panel (Internal Combustion) Replacement................ 360 Remove and Disassemble.................................................. 360 Assemble and Install.................................................... 363 Cluster Display Panel (Electric Lift Truck) Replacement..................... 365 Display Panel Assembly, Replace......................................... 365 LED Indicators.......................................................... 365 Battery Indicators...................................................... 366 Digital Display (Enhanced Display Panel Only)........................... 366 Status Code or Performance Level Switches and LED indicators (En........ 366 Standard Display Panel Parts, Replace................................... 366 Enhanced Display Panel Parts, Replace................................... 367 Curtis 1215 Display Panel Replacement....................................... 367 Remove.................................................................. 367 Install................................................................. 367 tables.......................................................................... 345 Table 1. Instrument Cluster, Internal Combustion............................ 349 Dash................................................................................ 371 toc............................................................................. 371 Mast........................................................................ 371 Safety Precautions Maintenance and Repair................................... 372 General..................................................................... 375 Description and Operation................................................... 375 Carriages............................................................... 375 Mast Mounts............................................................. 377 Two-Stage Mast, Limited Free-Lift (LFL)..................................... 379 Description and Operation............................................... 379 Two-Stage Mast, Full Free-Lift (FFL)........................................ 381 Description and Operation............................................... 381 Three-Stage Mast, Full Free-Lift (FFL)...................................... 383 Description and Operation............................................... 383 Four-Stage Mast............................................................. 386 Description and Operation............................................... 386 Cylinder Cushion During Lifting Sequence.................................... 389 Cylinder Cushion During Lowering Sequence................................... 390 DC Motor Maint. (1)................................................................. 393 toc............................................................................. 393 DC Motor Maintenance........................................................ 393 Safety Precautions Maintenance and Repair................................... 394 General..................................................................... 397 Brush and Commutator Inspection............................................. 397 Hydraulic Pump Motor and Traction Motor................................. 397 Steering Pump Motor..................................................... 400 Normal Commutator Surface............................................... 401 Commutator Problems..................................................... 401 Brush Replacement........................................................... 404 Stoning the Commutator...................................................... 406 Motors Repair............................................................... 408 Disassemble............................................................. 408 Traction Motor and Hydraulic Pump Motor............................. 408 Steering Pump Motor................................................. 410 Assemble................................................................ 412 Traction Motor and Hydraulic Pump Motor............................. 412 Steering Pump Motor................................................. 413 Brush Alignment, Traction and Hydraulic Motors.............................. 415 Tests for Damaged Field and Armature........................................ 415 Test for an Open Circuit in One Armature Winding........................ 415 Test for Short Circuit in One Armature Winding.......................... 416 Test for Short Circuit to Armature Shaft................................ 416 Test for Open Circuit in Field Coil..................................... 416 Test for Short Circuit in Field Coil.................................... 417 Test for Short Circuit Between Field and Motor Case..................... 417 Brush Holder Test....................................................... 417 Troubleshooting............................................................. 417 tables.......................................................................... 393 Table 1. Normal Commutator Surfaces......................................... 400 Table 2. Commutator Problems................................................ 401 Table 3. Brush Wear Replacement Guide....................................... 404 DC Motor Maint...................................................................... 423 toc............................................................................. 423 DC Motor Maintenance........................................................ 423 Safety Precautions Maintenance and Repair................................... 424 General..................................................................... 427 Brush and Commutator Inspection............................................. 427 Hydraulic Pump Motor and Traction Motor................................. 427 Steering Pump Motor..................................................... 430 Normal Commutator Surface............................................... 431 Commutator Problems..................................................... 431 Brush Replacement........................................................... 434 Stoning the Commutator...................................................... 436 Motors Repair............................................................... 438 Disassemble............................................................. 438 Traction Motor and Hydraulic Pump Motor............................. 438 Steering Pump Motor................................................. 440 Assemble................................................................ 442 Traction Motor and Hydraulic Pump Motor............................. 442 Steering Pump Motor................................................. 443 Brush Alignment, Traction and Hydraulic Motors.............................. 445 Tests for Damaged Field and Armature........................................ 445 Test for an Open Circuit in One Armature Winding........................ 445 Test for Short Circuit in One Armature Winding.......................... 446 Test for Short Circuit to Armature Shaft................................ 446 Test for Open Circuit in Field Coil..................................... 446 Test for Short Circuit in Field Coil.................................... 447 Test for Short Circuit Between Field and Motor Case..................... 447 Brush Holder Test....................................................... 447 Troubleshooting............................................................. 447 tables.......................................................................... 423 Table 1. Normal Commutator Surfaces......................................... 430 Table 2. Commutator Problems................................................ 431 Table 3. Brush Wear Replacement Guide....................................... 434 Drive Axle (1)...................................................................... 453 toc............................................................................. 453 Drive Axle, Speed Reducer, and Differential................................. 453 Safety Precautions Maintenance and Repair................................... 454 General..................................................................... 457 Description................................................................. 457 Drive Axle, Speed Reducer, and Differential Repair.......................... 460 Drive Axle, Remove...................................................... 460 Drive Axle, Disassemble............................................. 461 Speed Reducer and Differential, Disassemble......................... 461 Clean................................................................... 463 Inspect................................................................. 463 Assemble................................................................ 464 Speed Reducer and Differential, Assemble............................ 464 Input Gear Assembly, Install.................................... 464 New Pinion Assembly, Install.................................... 465 Drive Axle, Assemble................................................ 471 Drive Axle Assembly, Install............................................ 472 Torque Specifications....................................................... 473 Wheel Nuts.............................................................. 473 Axle Shaft Capscrews.................................................... 473 Axle Hangers to Frame................................................... 473 Back Plate to Axle Mount Capscrews...................................... 473 Wheel Cylinder Capscrews................................................ 473 Ring Gear to Differential Case.......................................... 474 Differential Case Halves................................................ 474 Bearing Cap Capscrews................................................... 474 Retainer Capscrews...................................................... 474 Axle Housing to Differential Housing.................................... 474 Pinion Nut.............................................................. 474 Speed Reducer Housing to Differential Housing........................... 474 Traction Motor to Transmission.......................................... 474 Troubleshooting............................................................. 474 tables.......................................................................... 453 Table 1. Adjustment of Shims for Pinion Assembly............................ 465 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 469 Drive Axle.......................................................................... 477 toc............................................................................. 477 Drive Axle, Speed Reducer, and Differential................................. 477 Safety Precautions Maintenance and Repair................................... 478 General..................................................................... 481 Description................................................................. 481 Drive Axle, Speed Reducer, and Differential Repair.......................... 484 Drive Axle, Remove...................................................... 484 Drive Axle, Disassemble............................................. 485 Speed Reducer and Differential, Disassemble......................... 485 Clean................................................................... 487 Inspect................................................................. 487 Assemble................................................................ 488 Speed Reducer and Differential, Assemble............................ 488 Input Gear Assembly, Install.................................... 488 New Pinion Assembly, Install.................................... 489 Drive Axle, Assemble................................................ 495 Drive Axle Assembly, Install............................................ 496 Torque Specifications....................................................... 497 Wheel Nuts.............................................................. 497 Axle Shaft Capscrews.................................................... 497 Axle Hangers to Frame................................................... 497 Back Plate to Axle Mount Capscrews...................................... 497 Wheel Cylinder Capscrews................................................ 497 Ring Gear to Differential Case.......................................... 498 Differential Case Halves................................................ 498 Bearing Cap Capscrews................................................... 498 Retainer Capscrews...................................................... 498 Axle Housing to Differential Housing.................................... 498 Pinion Nut.............................................................. 498 Speed Reducer Housing to Differential Housing........................... 498 Traction Motor to Transmission.......................................... 498 Troubleshooting............................................................. 498 tables.......................................................................... 477 Table 1. Adjustment of Shims for Pinion Assembly............................ 489 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 493 Electrical System (1)............................................................... 501 toc............................................................................. 501 Electrical System........................................................... 501 Safety Precautions Maintenance and Repair................................... 502 General..................................................................... 507 Description................................................................. 508 ZX Series Display Panels................................................ 508 Display Panel....................................................... 508 Basic Display Panels................................................ 508 Early Display Panel............................................. 508 Later Display Panel............................................. 508 Performance Display................................................. 510 Brush Wear Indicators............................................... 514 SEM Display Panels - Features........................................... 514 Descriptions of Common Features..................................... 514 LED Symbol Indicators - SEM..................................... 514 LCD Screen...................................................... 514 Battery Discharge Indicator (BDI)............................... 514 Service Reminder................................................ 515 Status Codes.................................................... 515 Hourmeter....................................................... 516 Additional Features of Premium Display Panel........................ 516 Descriptions of Additional Features................................. 517 LCD Screen...................................................... 517 Operator Passwords.............................................. 517 Daily Checklist and Service Items............................... 517 Performance Modes............................................... 517 Status Code Lists............................................... 517 Adjustment of BDI............................................... 518 SEM Display Panel Indicators............................................ 518 All Indicator Symbols............................................... 518 Hourmeter Indicator Symbol.......................................... 518 Wrench Symbol....................................................... 518 Battery Symbol...................................................... 518 Battery Discharge Indicator (BDI)................................... 518 Brake Fluid Too Low Symbol.......................................... 518 Parking Brake Symbol................................................ 518 Fasten Seat Belt Symbol............................................. 518 LCD Screen (Standard Display Panel)................................. 518 Additional Components of Premium Display Panel.......................... 519 Alpha Numerical Screen.............................................. 519 STAR Push Button.................................................... 519 Push Buttons ##1 Through ##5 - SEM.................................. 519 Other Control Components................................................ 519 Display Panel Components Replacement........................................ 520 ZX Panel Replacement.................................................... 520 Display Panel Assembly.................................................. 520 Key Switch, Replace..................................................... 520 Indicator LEDs.......................................................... 520 Battery Indicators...................................................... 520 Digital Display (Performance Display Panel Only)........................ 521 Status Code or Performance Level Switches and Indicator LEDs (Pe........ 521 Basic Display Panel, Replace Parts...................................... 521 Performance Display Panel, Replace Parts................................ 524 SEM Display Panel Replacement............................................... 524 Motor Controller (SR or SP) Replacement..................................... 526 Remove.................................................................. 526 Install................................................................. 526 Control Components Replacement.............................................. 527 Start Switch, Replace................................................... 527 Brake Light Switch, Replace............................................. 527 Seat Switch, Replace.................................................... 528 External Seat Switch, Adjust............................................ 529 Switch for Optional Seat Brake, Replace................................. 529 Parking Brake Switch, Replace........................................... 530 Direction Switches (MONOTROL Pedal), Replace............................ 531 Direction Control Switches (Steering Column), Replace................... 532 Direction Control Switches, E70-120XL 3 (Steering Column)............... 533 Brake Fluid Switch, Replace............................................. 533 Brush Wear and Overtemperature Sensors.................................. 533 Rocker Switches for Lights.............................................. 533 Accelerator Position Sensor, Replace.................................... 534 On-Demand Steering Components........................................... 536 Lights, Converter, Relay, and Reverse Alarm............................. 538 Incandescent Brake, Tail, and Reverse Light Assembly, Replace....... 538 LED Brake, Tail, and Reverse Light Assembly, Replace................ 538 Remove.......................................................... 538 Install......................................................... 538 Flashing Light Assembly, Replace.................................... 539 Front, Rear Driving Light, or Spot Light Assemblies, Replace........ 539 Operator Compartment Light Assembly, Replace........................ 541 Converter, Replace.................................................. 541 Relay, Replace...................................................... 543 Reverse Alarm, Replace.............................................. 543 Horn and Horn Button.................................................... 543 Horn Switch and Cover............................................... 544 Hydraulic Pump Switches................................................. 544 Control and Power Fuses Check............................................... 545 ZX Motor Controllers.................................................... 545 SEM Motor Controllers................................................... 545 SEM Controller Field Diagnostic Procedure............................... 553 Armature FET Test................................................... 553 Field FET Test...................................................... 553 Brush Wear and Overtemperature Sensors Check - ZX Motor Controll............ 554 Thermal Sensors - SEM Motor Controllers Check............................... 555 Start Switch Adjustment..................................................... 556 Accelerator Potentiometer and Start Switch, E70-120XL, E70-120XL........ 556 E70-120XL........................................................... 557 E70-120XL 3......................................................... 558 Direction Switches (MONOTROL)........................................... 558 Brake Light Switch Adjustment............................................... 559 Seat Switch Check........................................................... 560 Optional Seat Brake Switch Adjustment....................................... 560 Parking Brake Switch Adjustment............................................. 561 Direction Switches Check.................................................... 562 Monotrol Pedal.......................................................... 562 Steering Column......................................................... 562 Hydraulic Pump Switch Adjustment............................................ 562 MONOTROL or Accelerator Pedal Adjustment.................................... 563 Accelerator Position Sensor Adjustment...................................... 564 Electrical System................................................................... 569 toc............................................................................. 569 Electrical System........................................................... 569 Safety Precautions Maintenance and Repair................................... 570 General..................................................................... 575 Description................................................................. 576 ZX Series Display Panels................................................ 576 Display Panel....................................................... 576 Basic Display Panels................................................ 576 Early Display Panel............................................. 576 Later Display Panel............................................. 576 Performance Display................................................. 578 Brush Wear Indicators............................................... 582 SEM Display Panels - Features........................................... 582 Descriptions of Common Features..................................... 582 LED Symbol Indicators - SEM..................................... 582 LCD Screen...................................................... 582 Battery Discharge Indicator (BDI)............................... 582 Service Reminder................................................ 583 Status Codes.................................................... 583 Hourmeter....................................................... 584 Additional Features of Premium Display Panel........................ 584 Descriptions of Additional Features................................. 585 LCD Screen...................................................... 585 Operator Passwords.............................................. 585 Daily Checklist and Service Items............................... 585 Performance Modes............................................... 585 Status Code Lists............................................... 585 Adjustment of BDI............................................... 586 SEM Display Panel Indicators............................................ 586 All Indicator Symbols............................................... 586 Hourmeter Indicator Symbol.......................................... 586 Wrench Symbol....................................................... 586 Battery Symbol...................................................... 586 Battery Discharge Indicator (BDI)................................... 586 Brake Fluid Too Low Symbol.......................................... 586 Parking Brake Symbol................................................ 586 Fasten Seat Belt Symbol............................................. 586 LCD Screen (Standard Display Panel)................................. 586 Additional Components of Premium Display Panel.......................... 587 Alpha Numerical Screen.............................................. 587 STAR Push Button.................................................... 587 Push Buttons ##1 Through ##5 - SEM.................................. 587 Other Control Components................................................ 587 Display Panel Components Replacement........................................ 588 ZX Panel Replacement.................................................... 588 Display Panel Assembly.................................................. 588 Key Switch, Replace..................................................... 588 Indicator LEDs.......................................................... 588 Battery Indicators...................................................... 588 Digital Display (Performance Display Panel Only)........................ 589 Status Code or Performance Level Switches and Indicator LEDs (Pe........ 589 Basic Display Panel, Replace Parts...................................... 589 Performance Display Panel, Replace Parts................................ 592 SEM Display Panel Replacement............................................... 592 Motor Controller (SR or SP) Replacement..................................... 594 Remove.................................................................. 594 Install................................................................. 594 Control Components Replacement.............................................. 595 Start Switch, Replace................................................... 595 Brake Light Switch, Replace............................................. 595 Seat Switch, Replace.................................................... 596 External Seat Switch, Adjust............................................ 597 Switch for Optional Seat Brake, Replace................................. 597 Parking Brake Switch, Replace........................................... 598 Direction Switches (MONOTROL Pedal), Replace............................ 599 Direction Control Switches (Steering Column), Replace................... 600 Direction Control Switches, E70-120XL 3 (Steering Column)............... 601 Brake Fluid Switch, Replace............................................. 601 Brush Wear and Overtemperature Sensors.................................. 601 Rocker Switches for Lights.............................................. 601 Accelerator Position Sensor, Replace.................................... 602 On-Demand Steering Components........................................... 604 Lights, Converter, Relay, and Reverse Alarm............................. 606 Incandescent Brake, Tail, and Reverse Light Assembly, Replace....... 606 LED Brake, Tail, and Reverse Light Assembly, Replace................ 606 Remove.......................................................... 606 Install......................................................... 606 Flashing Light Assembly, Replace.................................... 607 Front, Rear Driving Light, or Spot Light Assemblies, Replace........ 607 Operator Compartment Light Assembly, Replace........................ 609 Converter, Replace.................................................. 609 Relay, Replace...................................................... 611 Reverse Alarm, Replace.............................................. 611 Horn and Horn Button.................................................... 611 Horn Switch and Cover............................................... 612 Hydraulic Pump Switches................................................. 612 Control and Power Fuses Check............................................... 613 ZX Motor Controllers.................................................... 613 SEM Motor Controllers................................................... 613 SEM Controller Field Diagnostic Procedure............................... 621 Armature FET Test................................................... 621 Field FET Test...................................................... 621 Brush Wear and Overtemperature Sensors Check - ZX Motor Controll............ 622 Thermal Sensors - SEM Motor Controllers Check............................... 623 Start Switch Adjustment..................................................... 624 Accelerator Potentiometer and Start Switch, E70-120XL, E70-120XL........ 624 E70-120XL........................................................... 625 E70-120XL 3......................................................... 626 Direction Switches (MONOTROL)........................................... 626 Brake Light Switch Adjustment............................................... 627 Seat Switch Check........................................................... 628 Optional Seat Brake Switch Adjustment....................................... 628 Parking Brake Switch Adjustment............................................. 629 Direction Switches Check.................................................... 630 Monotrol Pedal.......................................................... 630 Steering Column......................................................... 630 Hydraulic Pump Switch Adjustment............................................ 630 MONOTROL or Accelerator Pedal Adjustment.................................... 631 Accelerator Position Sensor Adjustment...................................... 632 EV 100 Diagrams (1)................................................................. 637 toc............................................................................. 637 Electrical Diagrams......................................................... 637 Safety Precautions Maintenance and Repair................................... 638 EV 100 Diagrams..................................................................... 703 toc............................................................................. 703 Electrical Diagrams......................................................... 703 Safety Precautions Maintenance and Repair................................... 704 EV-100 Motor Controller (1)......................................................... 769 ................................................................................ 769 ................................................................................ 770 ................................................................................ 771 ................................................................................ 772 ................................................................................ 773 ................................................................................ 774 ................................................................................ 775 ................................................................................ 776 ................................................................................ 777 ................................................................................ 778 ................................................................................ 779 ................................................................................ 780 ................................................................................ 781 ................................................................................ 782 ................................................................................ 783 ................................................................................ 784 ................................................................................ 785 ................................................................................ 786 ................................................................................ 787 ................................................................................ 788 ................................................................................ 789 ................................................................................ 790 ................................................................................ 791 ................................................................................ 792 ................................................................................ 793 ................................................................................ 794 ................................................................................ 795 ................................................................................ 796 EV-100 Motor Controller............................................................. 797 ................................................................................ 797 ................................................................................ 798 ................................................................................ 799 ................................................................................ 800 ................................................................................ 801 ................................................................................ 802 ................................................................................ 803 ................................................................................ 804 ................................................................................ 805 ................................................................................ 806 ................................................................................ 807 ................................................................................ 808 ................................................................................ 809 ................................................................................ 810 ................................................................................ 811 ................................................................................ 812 ................................................................................ 813 ................................................................................ 814 ................................................................................ 815 ................................................................................ 816 ................................................................................ 817 ................................................................................ 818 ................................................................................ 819 ................................................................................ 820 ................................................................................ 821 ................................................................................ 822 ................................................................................ 823 ................................................................................ 824 EV100 WPC (1)....................................................................... 825 toc............................................................................. 825 Troubleshooting and Adjustments With a Computer............................. 825 Safety Precautions Maintenance and Repair................................... 826 Computer System............................................................. 829 Connect a PC to a Control Card.......................................... 830 Installation............................................................ 831 HYTECH™ Windows Software Program............................................ 831 How to Start the Program................................................ 831 DEMO Mode............................................................... 832 Selecting the Communications Port....................................... 834 Verification of Controller and Lift Truck............................... 835 Select Lift Truck Series................................................ 837 Controller Card Register Parameter List................................. 838 How to Change a Parameter............................................... 839 How to Save a Changed Parameter File.................................... 840 How to Load a Saved Parameter File...................................... 841 How to Show and Remove Saved Parameter Files............................ 842 How to Return to Factory Default Settings............................... 843 How to Save Changes to Control Card..................................... 844 How to View Status Codes................................................ 845 Saving Status Codes..................................................... 846 How to Show and Remove Saved Status Code Files.......................... 848 Closing and Clearing Status Code List................................... 848 How to View Saved Register Data and Saved Status Data................... 849 How to Save Register Data and Status Code Data In .RTF and .TXT ........ 851 GE Sentry™ Software Program................................................. 852 Installation............................................................ 852 Description............................................................. 852 How to Start GE SENTRY Program.......................................... 852 How to Reset MIN and MAX Display........................................ 857 Graphing Mode........................................................... 858 How to Exit GE SENTRY Program........................................... 859 tables.......................................................................... 825 Table 1. Cable Connections - Computer to Control............................ 829 Table 2. Adapter Pins (DB25F to DB9)........................................ 829 Table 3. Plug-Z Connection.................................................. 830 EV100 WPC........................................................................... 863 toc............................................................................. 863 Troubleshooting and Adjustments With a Computer............................. 863 Safety Precautions Maintenance and Repair................................... 864 Computer System............................................................. 867 Connect a PC to a Control Card.......................................... 868 Installation............................................................ 869 HYTECH™ Windows Software Program............................................ 869 How to Start the Program................................................ 869 DEMO Mode............................................................... 870 Selecting the Communications Port....................................... 872 Verification of Controller and Lift Truck............................... 873 Select Lift Truck Series................................................ 875 Controller Card Register Parameter List................................. 876 How to Change a Parameter............................................... 877 How to Save a Changed Parameter File.................................... 878 How to Load a Saved Parameter File...................................... 879 How to Show and Remove Saved Parameter Files............................ 880 How to Return to Factory Default Settings............................... 881 How to Save Changes to Control Card..................................... 882 How to View Status Codes................................................ 883 Saving Status Codes..................................................... 884 How to Show and Remove Saved Status Code Files.......................... 886 Closing and Clearing Status Code List................................... 886 How to View Saved Register Data and Saved Status Data................... 887 How to Save Register Data and Status Code Data In .RTF and .TXT ........ 889 GE Sentry™ Software Program................................................. 890 Installation............................................................ 890 Description............................................................. 890 How to Start GE SENTRY Program.......................................... 890 How to Reset MIN and MAX Display........................................ 895 Graphing Mode........................................................... 896 How to Exit GE SENTRY Program........................................... 897 tables.......................................................................... 863 Table 1. Cable Connections - Computer to Control............................ 867 Table 2. Adapter Pins (DB25F to DB9)........................................ 867 Table 3. Plug-Z Connection.................................................. 868 EV100ZX Controller (1).............................................................. 901 toc............................................................................. 901 EV-100ZX™ SCR Motor Controller.............................................. 901 Safety Precautions Maintenance and Repair................................... 902 General..................................................................... 907 Model Number Data For EV-100ZX Controller............................... 908 Register Parameters......................................................... 922 General................................................................. 922 Function Numbers........................................................ 922 Control Card, Checks and Adjustments........................................ 922 Handset..................................................................... 923 How to Check and Adjust Registers....................................... 923 How to Scroll through Fault Codes and Clear Them........................ 923 Checks and Adjustments on Workbench..................................... 924 When Handset Is Connected to Control Card Installed In Lift Truc........ 925 Function Numbers 1 through 15........................................... 926 Function Numbers 16 through 30.......................................... 926 Function Numbers 48 through 62.......................................... 926 Control Cards............................................................... 927 Function Number Descriptions............................................ 927 Traction Control Cards (Label Letters - ZH and ZY)...................... 927 Function Number 1 STORED STATUS CODE................................ 927 Function Number 2 CREEP SPEED....................................... 928 Function Number 3 CONTROLLED ACCELERATION AND 1A TIME............... 928 Function Number 4 CURRENT LIMIT..................................... 928 Function Number 5 PLUGGING DISTANCE (CURRENT)....................... 928 Function Number 6 1A DROP OUT CURRENT............................... 928 Function Number 7 FIELD WEAKENING PICK UP........................... 928 Function Number 8 FIELD WEAKENING DROP OUT.......................... 929 Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT................ 929 Function Number 10 REGENERATIVE BRAKING START....................... 929 Function Number 13 SPEED LIMIT 3 (SL3).............................. 929 Function Number 14 INTERNAL RESISTANCE COMPENSATION................. 930 Function Number 15 BATTERY VOLTS.................................... 930 Function Numbers GREATER THAN 15.................................... 930 Function Number 16 PEDAL POSITION PLUG.............................. 930 Function Number 17 CARD TYPE SELECTION.............................. 931 Function Number 18 STEERING PUMP TIME DELAY......................... 931 Function Number 19 MAINTENANCE ALERT (Tens/Units)................... 931 Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)........... 931 Function Number 21 MAINTENANCE SPEED LIMIT.......................... 931 Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS............. 931 Function Number 29 HOURMETER (Tens/Units)........................... 932 Function Number 30 HOURMETER (Thousands/Hundreds)................... 932 Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE............ 932 Function Number 48 CONTROLLED ACCELERATION AND 1A TIME.............. 932 Function Number 49 FIELD WEAKENING PICK UP.......................... 932 Function Number 50 SPEED LIMIT 1.................................... 932 Function Number 52 CONTROLLED ACCELERATION AND 1A TIME.............. 933 Function Number 53 FIELD WEAKENING PICK UP.......................... 933 Function Number 54 SPEED LIMIT 1.................................... 933 Function Number 56 CONTROLLED ACCELERATION AND 1A TIME.............. 933 Function Number 57 FIELD WEAKENING PICK UP.......................... 933 Function Number 58 SPEED LIMIT 1.................................... 933 Function Number 60 CONTROLLED ACCELERATION AND 1A TIME.............. 934 Function Number 61 FIELD WEAKENING PICK UP.......................... 934 Pump Control Card (Label Letter ZP)..................................... 934 Function Number 1 STORED STATUS CODE................................ 934 Function Number 2 INTERNAL RESISTANCE COMPENSATION START............ 934 Function Number 3 CONTROLLED ACCELERATION........................... 934 Function Number 4 CURRENT LIMIT..................................... 934 Function Number 7 CONTROLLED ACCELERATION COMPENSATION.............. 934 Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and S.... 935 Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lif.... 935 Function Number 13 SPEED LIMIT 3 (SL3).............................. 935 Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift.................... 935 Function Numbers Greater Than 15.................................... 935 Function Number 16 INTERNAL RESISTANCE COMPENSATION................. 935 Function Number 17 CARD TYPE SELECTION.............................. 936 Function Numbers 18 through 28 TEMPORARY DATA REGISTERS............. 936 Function Number 29 HOURMETER (Tens/Units)........................... 936 Function Number 30 HOURMETER (Thousands/Hundreds)................... 936 Function Number 48 CONTROLLED ACCELERATION.......................... 936 Function Number 49 SPEED LIMIT 2.................................... 936 Function Number 50 SPEED LIMIT 3.................................... 936 Function Number 52 CONTROLLED ACCELERATION.......................... 936 Function Number 53 SPEED LIMIT 2.................................... 937 Function Number 54 SPEED LIMIT 3.................................... 937 Function Number 56 CONTROLLED ACCELERATION.......................... 937 Function Number 57 SPEED LIMIT 2.................................... 937 Function Number 58 SPEED LIMIT 3.................................... 937 Function Number 60 CONTROLLED ACCELERATION.......................... 937 Function Number 61 SPEED LIMIT 2.................................... 937 Function Number 62 SPEED LIMIT 3.................................... 937 Register Parameters..................................................... 937 Troubleshooting............................................................. 938 General................................................................. 938 Status Codes............................................................ 939 Register Maps........................................................... 941 Status Code Charts.......................................................... 952 EV-100ZX SCR Motor Controller Repair........................................ 994 Fuses................................................................... 996 SCR, Check.............................................................. 996 SCR Assembly............................................................ 996 Thermal Protector....................................................... 997 SCR 1 Assembly, Replace................................................. 997 OFF Circuit for SCR 1................................................... 997 Reactor Assembly, Check............................................. 997 Suppressors for SCR 2 and SCR 5, Check.............................. 997 SCR 2 and SCR 5, Check.............................................. 998 SCR 2 and SCR 5, Replace............................................ 998 Capacitor C1, Check................................................. 998 Diodes D3 and D4........................................................ 998 Diodes D3 and D4, Check............................................. 999 Diodes D3 and D4, Replace........................................... 999 Motor Current Sensor.................................................... 999 Contactors.............................................................. 999 Contactor, Repair...................................................1000 Control Card............................................................1002 Control Card Plugs......................................................1002 Brush Wear Indicators...............................................1003 Theory of Operation.........................................................1004 Electronic Speed Controls...............................................1004 Silicon Controlled Rectifier (SCR)..................................1004 Motor Circuit That Operates With Pulses.............................1005 Traction Circuit....................................................1007 Hydraulic Pump Motor................................................1007 SCR 1 OFF Circuit...................................................1007 SCR 1 OFF Operation.............................................1008 Induction Current from Motor............................................1010 Control Cards...........................................................1011 Pulse Monitor Trip (PMT) (Traction Circuit Only)....................1011 SRO Circuit (Traction Circuit Only).................................1011 Sequence of Operation...................................................1012 Control Card Adjustments (Traction Circuit).........................1013 Accelerator Control.................................................1016 SCR Control (Hydraulic Pump Motor)......................................1016 Contactors..............................................................1017 Circuit Protection......................................................1017 Traction Circuit Fuse...............................................1017 Current Limit.......................................................1017 Thermal Protection..................................................1018 Suppressors.........................................................1018 Truck Management Module (TMM1)..........................................1018 Display Panels..........................................................1019 Display Panel.......................................................1019 Basic Display.......................................................1019 Early Display Panel.............................................1020 Later Display Panel.............................................1021 Performance Display.................................................1022 Brush Wear Indicators...............................................1025 tables.......................................................................... 901 Table 1. Terminal and Plug Wire Connections for Control Card ZY,............ 914 Table 2. Terminal and Plug Wire Connections for Control Card ZH,............ 916 Table 3. Terminal and Plug Wire Connections for Control Card ZH,............ 918 Table 4. Terminal and Plug Wire Connections for Controller with ............ 920 Table 5. Status Codes List.................................................. 939 Table 6. Register Map for Control Cards ZH and ZY (Traction)................ 941 Table 7. Register Map for Control Card ZP (Hydraulic Pump).................. 946 Table 8. Terminal and Plug Wire Connections for TMM1 Module.................1019 EV100ZX Controller..................................................................1029 toc.............................................................................1029 EV-100ZX™ SCR Motor Controller..............................................1029 Safety Precautions Maintenance and Repair...................................1030 General.....................................................................1035 Model Number Data For EV-100ZX Controller...............................1036 Register Parameters.........................................................1050 General.................................................................1050 Function Numbers........................................................1050 Control Card, Checks and Adjustments........................................1050 Handset.....................................................................1051 How to Check and Adjust Registers.......................................1051 How to Scroll through Fault Codes and Clear Them........................1051 Checks and Adjustments on Workbench.....................................1052 When Handset Is Connected to Control Card Installed In Lift Truc........1053 Function Numbers 1 through 15...........................................1054 Function Numbers 16 through 30..........................................1054 Function Numbers 48 through 62..........................................1054 Control Cards...............................................................1055 Function Number Descriptions............................................1055 Traction Control Cards (Label Letters - ZH and ZY)......................1055 Function Number 1 STORED STATUS CODE................................1055 Function Number 2 CREEP SPEED.......................................1056 Function Number 3 CONTROLLED ACCELERATION AND 1A TIME...............1056 Function Number 4 CURRENT LIMIT.....................................1056 Function Number 5 PLUGGING DISTANCE (CURRENT).......................1056 Function Number 6 1A DROP OUT CURRENT...............................1056 Function Number 7 FIELD WEAKENING PICK UP...........................1056 Function Number 8 FIELD WEAKENING DROP OUT..........................1057 Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT................1057 Function Number 10 REGENERATIVE BRAKING START.......................1057 Function Number 13 SPEED LIMIT 3 (SL3)..............................1057 Function Number 14 INTERNAL RESISTANCE COMPENSATION.................1058 Function Number 15 BATTERY VOLTS....................................1058 Function Numbers GREATER THAN 15....................................1058 Function Number 16 PEDAL POSITION PLUG..............................1058 Function Number 17 CARD TYPE SELECTION..............................1059 Function Number 18 STEERING PUMP TIME DELAY.........................1059 Function Number 19 MAINTENANCE ALERT (Tens/Units)...................1059 Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)...........1059 Function Number 21 MAINTENANCE SPEED LIMIT..........................1059 Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS.............1059 Function Number 29 HOURMETER (Tens/Units)...........................1060 Function Number 30 HOURMETER (Thousands/Hundreds)...................1060 Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE............1060 Function Number 48 CONTROLLED ACCELERATION AND 1A TIME..............1060 Function Number 49 FIELD WEAKENING PICK UP..........................1060 Function Number 50 SPEED LIMIT 1....................................1060 Function Number 52 CONTROLLED ACCELERATION AND 1A TIME..............1061 Function Number 53 FIELD WEAKENING PICK UP..........................1061 Function Number 54 SPEED LIMIT 1....................................1061 Function Number 56 CONTROLLED ACCELERATION AND 1A TIME..............1061 Function Number 57 FIELD WEAKENING PICK UP..........................1061 Function Number 58 SPEED LIMIT 1....................................1061 Function Number 60 CONTROLLED ACCELERATION AND 1A TIME..............1062 Function Number 61 FIELD WEAKENING PICK UP..........................1062 Pump Control Card (Label Letter ZP).....................................1062 Function Number 1 STORED STATUS CODE................................1062 Function Number 2 INTERNAL RESISTANCE COMPENSATION START............1062 Function Number 3 CONTROLLED ACCELERATION...........................1062 Function Number 4 CURRENT LIMIT.....................................1062 Function Number 7 CONTROLLED ACCELERATION COMPENSATION..............1062 Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and S....1063 Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lif....1063 Function Number 13 SPEED LIMIT 3 (SL3)..............................1063 Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift....................1063 Function Numbers Greater Than 15....................................1063 Function Number 16 INTERNAL RESISTANCE COMPENSATION.................1063 Function Number 17 CARD TYPE SELECTION..............................1064 Function Numbers 18 through 28 TEMPORARY DATA REGISTERS.............1064 Function Number 29 HOURMETER (Tens/Units)...........................1064 Function Number 30 HOURMETER (Thousands/Hundreds)...................1064 Function Number 48 CONTROLLED ACCELERATION..........................1064 Function Number 49 SPEED LIMIT 2....................................1064 Function Number 50 SPEED LIMIT 3....................................1064 Function Number 52 CONTROLLED ACCELERATION..........................1064 Function Number 53 SPEED LIMIT 2....................................1065 Function Number 54 SPEED LIMIT 3....................................1065 Function Number 56 CONTROLLED ACCELERATION..........................1065 Function Number 57 SPEED LIMIT 2....................................1065 Function Number 58 SPEED LIMIT 3....................................1065 Function Number 60 CONTROLLED ACCELERATION..........................1065 Function Number 61 SPEED LIMIT 2....................................1065 Function Number 62 SPEED LIMIT 3....................................1065 Register Parameters.....................................................1065 Troubleshooting.............................................................1066 General.................................................................1066 Status Codes............................................................1067 Register Maps...........................................................1069 Status Code Charts..........................................................1080 EV-100ZX SCR Motor Controller Repair........................................1122 Fuses...................................................................1124 SCR, Check..............................................................1124 SCR Assembly............................................................1124 Thermal Protector.......................................................1125 SCR 1 Assembly, Replace.................................................1125 OFF Circuit for SCR 1...................................................1125 Reactor Assembly, Check.............................................1125 Suppressors for SCR 2 and SCR 5, Check..............................1125 SCR 2 and SCR 5, Check..............................................1126 SCR 2 and SCR 5, Replace............................................1126 Capacitor C1, Check.................................................1126 Diodes D3 and D4........................................................1126 Diodes D3 and D4, Check.............................................1127 Diodes D3 and D4, Replace...........................................1127 Motor Current Sensor....................................................1127 Contactors..............................................................1127 Contactor, Repair...................................................1128 Control Card............................................................1130 Control Card Plugs......................................................1130 Brush Wear Indicators...............................................1131 Theory of Operation.........................................................1132 Electronic Speed Controls...............................................1132 Silicon Controlled Rectifier (SCR)..................................1132 Motor Circuit That Operates With Pulses.............................1133 Traction Circuit....................................................1135 Hydraulic Pump Motor................................................1135 SCR 1 OFF Circuit...................................................1135 SCR 1 OFF Operation.............................................1136 Induction Current from Motor............................................1138 Control Cards...........................................................1139 Pulse Monitor Trip (PMT) (Traction Circuit Only)....................1139 SRO Circuit (Traction Circuit Only).................................1139 Sequence of Operation...................................................1140 Control Card Adjustments (Traction Circuit).........................1141 Accelerator Control.................................................1144 SCR Control (Hydraulic Pump Motor)......................................1144 Contactors..............................................................1145 Circuit Protection......................................................1145 Traction Circuit Fuse...............................................1145 Current Limit.......................................................1145 Thermal Protection..................................................1146 Suppressors.........................................................1146 Truck Management Module (TMM1)..........................................1146 Display Panels..........................................................1147 Display Panel.......................................................1147 Basic Display.......................................................1147 Early Display Panel.............................................1148 Later Display Panel.............................................1149 Performance Display.................................................1150 Brush Wear Indicators...............................................1153 tables..........................................................................1029 Table 1. Terminal and Plug Wire Connections for Control Card ZY,............1042 Table 2. Terminal and Plug Wire Connections for Control Card ZH,............1044 Table 3. Terminal and Plug Wire Connections for Control Card ZH,............1046 Table 4. Terminal and Plug Wire Connections for Controller with ............1048 Table 5. Status Codes List..................................................1067 Table 6. Register Map for Control Cards ZH and ZY (Traction)................1069 Table 7. Register Map for Control Card ZP (Hydraulic Pump)..................1074 Table 8. Terminal and Plug Wire Connections for TMM1 Module.................1147 EV100ZX Diagrams (1)................................................................1157 toc.............................................................................1157 Diagrams....................................................................1157 Safety Precautions Maintenance and Repair...................................1158 tables..........................................................................1157 Table 1. Terminal and Plug Wire Connections for Control Card JH.............1190 Table 2. Terminal and Plug Wire Connections for Hydraulic Pump C............1192 Table 3. Terminal and Plug Wire Connections for Control Card JH.............1193 Table 4. Terminal and Plug Wire Connections for TMM1 Module.................1195 Table 5. Terminal and Plug Wire Connections for Control Card JY.............1196 EV100ZX Diagrams....................................................................1207 toc.............................................................................1207 Diagrams....................................................................1207 Safety Precautions Maintenance and Repair...................................1208 tables..........................................................................1207 Table 1. Terminal and Plug Wire Connections for Control Card JH.............1240 Table 2. Terminal and Plug Wire Connections for Hydraulic Pump C............1242 Table 3. Terminal and Plug Wire Connections for Control Card JH.............1243 Table 4. Terminal and Plug Wire Connections for TMM1 Module.................1245 Table 5. Terminal and Plug Wire Connections for Control Card JY.............1246 EVT100 Programming (1)..............................................................1257 toc.............................................................................1257 EV-T100 Transistor Motor Controller.........................................1257 Safety Precautions Maintenance and Repair...................................1258 Register Parameters.........................................................1261 General.................................................................1261 Function Numbers........................................................1261 Control Card Checks and Adjustments.........................................1261 Register Parameters Tables..................................................1262 tables..........................................................................1257 Table 1. EV-T100 Parameters - E/J2.00-3.20XM (36 to 48V) [Tracti............1262 Table 2. EV-T100 Parameters - E2.00-3.20XM (36 to 48V) [Traction............1266 Table 3. EV-T100 Parameters - E/J2.00-3.20XM (72 to 80V) (Tracti............1270 Table 4. EV-T100 Parameters - E2.00-3.20XM (72 to 80V) (Traction............1273 Table 5. EV-T100 Parameters - E2.00-3.20XM (72 to 80V) (Traction............1277 Table 6. EV-T100 Parameters - All Lift Trucks (36 to 80 volts) (............1280 Table 7. EV-T100 Parameters - All Lift Trucks (24 to 80 volts) (............1284 EVT100 Programming..................................................................1291 toc.............................................................................1291 EV-T100 Transistor Motor Controller.........................................1291 Safety Precautions Maintenance and Repair...................................1292 Register Parameters.........................................................1295 General.................................................................1295 Function Numbers........................................................1295 Control Card Checks and Adjustments.........................................1295 Register Parameters Tables..................................................1296 tables..........................................................................1291 Table 1. EV-T100 Parameters - E/J2.00-3.20XM (36 to 48V) [Tracti............1296 Table 2. EV-T100 Parameters - E2.00-3.20XM (36 to 48V) [Traction............1300 Table 3. EV-T100 Parameters - E/J2.00-3.20XM (72 to 80V) (Tracti............1304 Table 4. EV-T100 Parameters - E2.00-3.20XM (72 to 80V) (Traction............1307 Table 5. EV-T100 Parameters - E2.00-3.20XM (72 to 80V) (Traction............1311 Table 6. EV-T100 Parameters - All Lift Trucks (36 to 80 volts) (............1314 Table 7. EV-T100 Parameters - All Lift Trucks (24 to 80 volts) (............1318 Frame (1)...........................................................................1325 toc.............................................................................1325 Frame.......................................................................1325 Safety Precautions Maintenance and Repair...................................1326 General.....................................................................1329 Description.................................................................1329 Main Frame..............................................................1329 Other Frame Weldments...................................................1332 Overhead Guard..........................................................1332 Overhead Guard Replacement..................................................1333 Remove..................................................................1333 Install.................................................................1333 Battery and Operator Restraint System, Hood and Seat Brake, and ............1340 Battery Restraint System................................................1340 Hood....................................................................1341 Hood With E-Hydraulics..................................................1342 Seat Brake..............................................................1343 Operator Restraint System and Seat Assembly.............................1343 Automatic Locking Retractor (ALR)...................................1343 Emergency Locking Retractor (ELR)...................................1344 Counterweight Replacement...................................................1345 Remove..................................................................1346 Install.................................................................1347 Traction Motor Replacement..................................................1348 Remove..................................................................1348 Install.................................................................1350 Hydraulic Tank Repair.......................................................1350 Inspect.................................................................1350 Clean...................................................................1351 Steam Method........................................................1351 Chemical Solution...................................................1352 Additional Preparations for Repair......................................1352 Small Leaks, Repair.....................................................1352 Large Leaks, Repair.....................................................1353 Preparations for Usage After Repair.....................................1353 Painting Instructions.......................................................1353 Safety Label Replacement....................................................1354 Battery Specifications......................................................1358 tables..........................................................................1325 Table 1. Counterweights.....................................................1346 Table 2. Lift Truck Models E2.00-3.20XM (E45-65XM, E45-65XM 2 ) ............1358 Table 3. Lift Truck Models E2.00-3.20XM (E40-65Z) (G108)....................1359 Frame...............................................................................1363 toc.............................................................................1363 Frame.......................................................................1363 Safety Precautions Maintenance and Repair...................................1364 General.....................................................................1367 Description.................................................................1367 Main Frame..............................................................1367 Other Frame Weldments...................................................1370 Overhead Guard..........................................................1370 Overhead Guard Replacement..................................................1371 Remove..................................................................1371 Install.................................................................1371 Battery and Operator Restraint System, Hood and Seat Brake, and ............1378 Battery Restraint System................................................1378 Hood....................................................................1379 Hood With E-Hydraulics..................................................1380 Seat Brake..............................................................1381 Operator Restraint System and Seat Assembly.............................1381 Automatic Locking Retractor (ALR)...................................1381 Emergency Locking Retractor (ELR)...................................1382 Counterweight Replacement...................................................1383 Remove..................................................................1384 Install.................................................................1385 Traction Motor Replacement..................................................1386 Remove..................................................................1386 Install.................................................................1388 Hydraulic Tank Repair.......................................................1388 Inspect.................................................................1388 Clean...................................................................1389 Steam Method........................................................1389 Chemical Solution...................................................1390 Additional Preparations for Repair......................................1390 Small Leaks, Repair.....................................................1390 Large Leaks, Repair.....................................................1391 Preparations for Usage After Repair.....................................1391 Painting Instructions.......................................................1391 Safety Label Replacement....................................................1392 Battery Specifications......................................................1396 tables..........................................................................1363 Table 1. Counterweights.....................................................1384 Table 2. Lift Truck Models E2.00-3.20XM (E45-65XM, E45-65XM 2 ) ............1396 Table 3. Lift Truck Models E2.00-3.20XM (E40-65Z) (G108)....................1397 Hyd. Control valve (1)..............................................................1401 toc.............................................................................1401 Manual hydraulic Control Valve..............................................1401 Safety Precautions Maintenance and Repair...................................1402 General.....................................................................1405 Description.................................................................1405 Operation...................................................................1408 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108); E1.50-2.00XM ........1408 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.00-3.20XM (J4........1408 Lift Section............................................................1410 Tilt Section............................................................1410 Tilt Backward.......................................................1410 Tilt Forward........................................................1410 Relief Valve............................................................1412 Main Control Valve Repair...................................................1413 Main Control Valve Without OPS Solenoid.................................1413 Remove..............................................................1413 Disassemble.........................................................1413 Clean and Inspect...................................................1417 Assemble............................................................1417 Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108); E1.5....1418 Install [J2.00-3.20XM (J40-65XM, J40-60XM 2 ) (A216) and J2.00-3....1418 Main Control Valve With OPS Solenoid....................................1418 Remove..............................................................1419 Disassemble.........................................................1419 Clean and Inspect...................................................1421 Relief Valve Repair.................................................1423 Assemble............................................................1424 Install.............................................................1425 Control Lever Linkage Repair................................................1425 Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), E1.50........1425 Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), ........1425 Assemble and Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114........1427 Control Valve Linkage Repair................................................1427 Remove and Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D1........1427 Assemble and Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114........1428 Control Lever Linkage Repair................................................1428 Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.00-3.........1428 Disassemble [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.........1430 Assemble and Install [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216........1430 Pressure Relief Valve Check and Adjustment..................................1431 Primary Relief Valve....................................................1431 Secondary Relief Valve..................................................1432 Troubleshooting.............................................................1433 Hyd. Control valve..................................................................1437 toc.............................................................................1437 Manual hydraulic Control Valve..............................................1437 Safety Precautions Maintenance and Repair...................................1438 General.....................................................................1441 Description.................................................................1441 Operation...................................................................1444 E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108); E1.50-2.00XM ........1444 J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.00-3.20XM (J4........1444 Lift Section............................................................1446 Tilt Section............................................................1446 Tilt Backward.......................................................1446 Tilt Forward........................................................1446 Relief Valve............................................................1448 Main Control Valve Repair...................................................1449 Main Control Valve Without OPS Solenoid.................................1449 Remove..............................................................1449 Disassemble.........................................................1449 Clean and Inspect...................................................1453 Assemble............................................................1453 Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108); E1.5....1454 Install [J2.00-3.20XM (J40-65XM, J40-60XM 2 ) (A216) and J2.00-3....1454 Main Control Valve With OPS Solenoid....................................1454 Remove..............................................................1455 Disassemble.........................................................1455 Clean and Inspect...................................................1457 Relief Valve Repair.................................................1459 Assemble............................................................1460 Install.............................................................1461 Control Lever Linkage Repair................................................1461 Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), E1.50........1461 Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108), ........1461 Assemble and Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114........1463 Control Valve Linkage Repair................................................1463 Remove and Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D1........1463 Assemble and Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114........1464 Control Lever Linkage Repair................................................1464 Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.00-3.........1464 Disassemble [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2.........1466 Assemble and Install [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216........1466 Pressure Relief Valve Check and Adjustment..................................1467 Primary Relief Valve....................................................1467 Secondary Relief Valve..................................................1468 Troubleshooting.............................................................1469 Hydraulics (1)......................................................................1473 toc.............................................................................1473 Hydraulic System............................................................1473 Safety Precautions Maintenance and Repair...................................1474 General.....................................................................1479 Description.................................................................1480 Hydraulic System........................................................1480 Operation...................................................................1490 Hydraulic System........................................................1490 Hydraulic Gear Pump.....................................................1501 Rotator Actuator Valve..................................................1501 Steering Pump...........................................................1501 Hydraulic Tank Repair.......................................................1512 Tank, Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108);........1512 Tank, Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2........1513 Tank, Remove [J2.00-3.20XM (J40-60Z) (B416)]............................1514 Hyraulic Tank [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E........1514 Inspect.................................................................1516 Small Leaks, Repair.....................................................1516 Large Leaks, Repair.....................................................1516 Clean...................................................................1516 Steam Method........................................................1516 Chemical Solution Method............................................1517 Additional Methods for Tank Repair......................................1517 Tank, Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ), (D114, F108........1517 Tank, Install [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J........1518 Tank, Install [J2.00-3.20XM (J40-65Z) (B416)]...........................1518 Filter Replacement..........................................................1519 All Lift Trucks Except [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS........1519 Remove..............................................................1519 Install.............................................................1520 Lift Truck Models [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D0........1520 Remove..............................................................1520 Install.............................................................1520 Lift truck Models [E2.00-3.20XM (E45-65Z) (G108) and E1.50-2.00X........1521 Remove..............................................................1521 Install.............................................................1521 Lift Truck Models [J2.00-3.20XM (J40-65Z) (B416)].......................1523 Remove..............................................................1523 Install.............................................................1523 Hydraulic Pump Repair.......................................................1526 Hydraulic Pump, Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D1........1526 Hydraulic Pump, Disassemble E1.50-3.20XM (E25-65XM, E25-65XM 2 )........1527 Inspect.................................................................1528 Clean...................................................................1528 Pump Seal Replace and Pump Assemble.....................................1528 Assemble Pump on Motor..................................................1528 Hydraulic Pump and Motor, Install [E1.50-3.20XM (E25-65XM, E25-6........1530 Hydraulic Pump, Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A2........1531 Hydraulic Pump, Disassemble [E3.50-5.50XL, E4.50XLS (E70-120Z, E........1532 Hydraulic Pump, Inspect [E3.50-5.50XL, E4.50XLS (E70-120Z, E100Z........1534 Hydraulic Pump, Clean [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)........1534 Hydraulic Pump, Assemble [E3.50-5.50XL, E4.50XLS (E70-120Z, E100........1534 Hydraulic Pump and Motor, Install [J2.00-3.20XM (J40-60XM, J40-6........1534 Main Control Valve Repair...................................................1536 Steering Pump Repair........................................................1537 Pump, Remove and Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2........1537 Pump, Remove and Disassemble [J2.00-3.20XM (J40-60XM, J40-60XM 2........1538 Pump, Assemble and Install..............................................1540 Rotary Actuator Valve Repair................................................1541 Disassemble, Clean, and Inspect.........................................1541 Assemble................................................................1541 Steering Control Unit Replacement...........................................1542 Remove..................................................................1542 Install.................................................................1543 Steering Cylinder Repair....................................................1549 Main Control Valve Check and Adjust.........................................1549 Steering Relief Valve Check and Adjust......................................1550 Specifications..............................................................1551 Relief Valve Pressures*.................................................1551 Hydraulic Tank Capacity (dipstick full mark)............................1551 Hydraulic Pump Capacities - All Models Except E3.50-5.50XL, E4.5........1551 Hydraulic Pump Capacities - Models E3.50-5.50XL, E4.50XLS (E70-1........1551 Troubleshooting.............................................................1552 Steering................................................................1552 Steering Housing and Steering Control Unit..............................1553 Hydraulic System........................................................1554 Hydraulics..........................................................................1559 toc.............................................................................1559 Hydraulic System............................................................1559 Safety Precautions Maintenance and Repair...................................1560 General.....................................................................1565 Description.................................................................1566 Hydraulic System........................................................1566 Operation...................................................................1576 Hydraulic System........................................................1576 Hydraulic Gear Pump.....................................................1587 Rotator Actuator Valve..................................................1587 Steering Pump...........................................................1587 Hydraulic Tank Repair.......................................................1598 Tank, Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D114, F108);........1598 Tank, Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J2........1599 Tank, Remove [J2.00-3.20XM (J40-60Z) (B416)]............................1600 Hyraulic Tank [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E........1600 Inspect.................................................................1602 Small Leaks, Repair.....................................................1602 Large Leaks, Repair.....................................................1602 Clean...................................................................1602 Steam Method........................................................1602 Chemical Solution Method............................................1603 Additional Methods for Tank Repair......................................1603 Tank, Install [E1.50-3.20XM (E25-65XM, E25-65XM 2 ), (D114, F108........1603 Tank, Install [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A216) and J........1604 Tank, Install [J2.00-3.20XM (J40-65Z) (B416)]...........................1604 Filter Replacement..........................................................1605 All Lift Trucks Except [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS........1605 Remove..............................................................1605 Install.............................................................1606 Lift Truck Models [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D0........1606 Remove..............................................................1606 Install.............................................................1606 Lift truck Models [E2.00-3.20XM (E45-65Z) (G108) and E1.50-2.00X........1607 Remove..............................................................1607 Install.............................................................1607 Lift Truck Models [J2.00-3.20XM (J40-65Z) (B416)].......................1609 Remove..............................................................1609 Install.............................................................1609 Hydraulic Pump Repair.......................................................1612 Hydraulic Pump, Remove [E1.50-3.20XM (E25-65XM, E25-65XM 2 ) (D1........1612 Hydraulic Pump, Disassemble E1.50-3.20XM (E25-65XM, E25-65XM 2 )........1613 Inspect.................................................................1614 Clean...................................................................1614 Pump Seal Replace and Pump Assemble.....................................1614 Assemble Pump on Motor..................................................1614 Hydraulic Pump and Motor, Install [E1.50-3.20XM (E25-65XM, E25-6........1616 Hydraulic Pump, Remove [J2.00-3.20XM (J40-60XM, J40-60XM 2 ) (A2........1617 Hydraulic Pump, Disassemble [E3.50-5.50XL, E4.50XLS (E70-120Z, E........1618 Hydraulic Pump, Inspect [E3.50-5.50XL, E4.50XLS (E70-120Z, E100Z........1620 Hydraulic Pump, Clean [E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)........1620 Hydraulic Pump, Assemble [E3.50-5.50XL, E4.50XLS (E70-120Z, E100........1620 Hydraulic Pump and Motor, Install [J2.00-3.20XM (J40-60XM, J40-6........1620 Main Control Valve Repair...................................................1622 Steering Pump Repair........................................................1623 Pump, Remove and Disassemble [E1.50-3.20XM (E25-65XM, E25-65XM 2........1623 Pump, Remove and Disassemble [J2.00-3.20XM (J40-60XM, J40-60XM 2........1624 Pump, Assemble and Install..............................................1626 Rotary Actuator Valve Repair................................................1627 Disassemble, Clean, and Inspect.........................................1627 Assemble................................................................1627 Steering Control Unit Replacement...........................................1628 Remove..................................................................1628 Install.................................................................1629 Steering Cylinder Repair....................................................1635 Main Control Valve Check and Adjust.........................................1635 Steering Relief Valve Check and Adjust......................................1636 Specifications..............................................................1637 Relief Valve Pressures*.................................................1637 Hydraulic Tank Capacity (dipstick full mark)............................1637 Hydraulic Pump Capacities - All Models Except E3.50-5.50XL, E4.5........1637 Hydraulic Pump Capacities - Models E3.50-5.50XL, E4.50XLS (E70-1........1637 Troubleshooting.............................................................1638 Steering................................................................1638 Steering Housing and Steering Control Unit..............................1639 Hydraulic System........................................................1640 Mast repair (1).....................................................................1645 toc.............................................................................1645 Mast Repairs................................................................1645 Safety Precautions Maintenance and Repair...................................1646 General.....................................................................1649 Safety Procedures When Working Near Mast....................................1650 Fork Repair.................................................................1652 Remove..................................................................1652 Install.................................................................1652 Carriages Repair............................................................1654 Standard Carriage, Remove...............................................1654 Hang-On Sideshift Carriage, Remove......................................1654 Standard Carriage and Hang-On Sideshift Carriage, Repair................1656 Standard Carriage, Install..............................................1657 Hang-On Sideshift Carriage, Install.....................................1658 Integral Sideshift Carriage.............................................1658 Remove..............................................................1658 Clean and Inspect...................................................1662 Repair..............................................................1663 Install.............................................................1664 Mast Repair.................................................................1665 Remove..................................................................1665 Two-Stage LFL and Two-Stage FFL Masts, Disassemble......................1668 Three-Stage FFL Mast....................................................1675 Disassemble.........................................................1675 Mast and Chains, Clean and Inspect..................................1679 Two-Stage LFL and Two-Stage FFL Mast, Assemble..........................1680 Three-Stage FFL Mast, Assemble..........................................1681 Install.................................................................1682 Lift Cylinders Repair.......................................................1684 Main Lift Cylinders, Remove.............................................1684 Free-Lift Cylinder, Remove..............................................1684 Cylinders, Disassemble..................................................1685 Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder........1685 Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder.........1687 Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift ....1687 Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift ....1688 Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas....1689 Clean and Inspect.......................................................1690 Cylinders, Assemble.....................................................1690 Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder........1690 Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder.........1691 Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift ....1692 Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift ....1693 Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas....1693 Main Lift Cylinders, Install............................................1694 Free-Lift Cylinder, Install.............................................1694 Header Hose Arrangements....................................................1695 Two-Stage LFL Mast, New Hose Install....................................1695 Two-Stage LFL Mast, Adjust Hoses After Installation.....................1700 Two-Stage FFL Mast, New Hose Install....................................1701 Two-Stage FFL Mast, Adjust Hoses After Installation.....................1707 Three-Stage FFL Mast, New Hose Install..................................1707 Three-Stage FFL Mast, Adjust Hoses After Installation...................1718 Header Hose Arrangement.....................................................1719 Two-Stage LFL Mast, New Hose Install....................................1719 Two-Stage LFL Mast, Adjust Hoses After Installation.....................1723 Two-Stage FFL Mast, New Hose Install....................................1724 Two-Stage FFL Mast, Adjust Hoses After Installation.....................1730 Three-Stage FFL Mast, New Hose Install..................................1730 Three-Stage FFL Mast, Adjust Hoses After Install........................1739 Lift and Tilt System Leak Check.............................................1740 Lift Cylinders Leak Check...............................................1740 Tilt Cylinders Leak Check...............................................1740 Tilt Cylinders Adjustment...................................................1741 Lift Chains Adjustment......................................................1743 Mast Adjustment.............................................................1745 Carriage Adjustment.........................................................1747 Troubleshooting.............................................................1748 tables..........................................................................1645 Table 1. Hook-Type Carriage Chain Adjustment................................1743 Table 2. Pin-Type Carriage Chain Adjustment.................................1744 Mast repair.........................................................................1751 toc.............................................................................1751 Mast Repairs................................................................1751 Safety Precautions Maintenance and Repair...................................1752 General.....................................................................1755 Safety Procedures When Working Near Mast....................................1756 Fork Repair.................................................................1758 Remove..................................................................1758 Install.................................................................1758 Carriages Repair............................................................1760 Standard Carriage, Remove...............................................1760 Hang-On Sideshift Carriage, Remove......................................1760 Standard Carriage and Hang-On Sideshift Carriage, Repair................1762 Standard Carriage, Install..............................................1763 Hang-On Sideshift Carriage, Install.....................................1764 Integral Sideshift Carriage.............................................1764 Remove..............................................................1764 Clean and Inspect...................................................1768 Repair..............................................................1769 Install.............................................................1770 Mast Repair.................................................................1771 Remove..................................................................1771 Two-Stage LFL and Two-Stage FFL Masts, Disassemble......................1774 Three-Stage FFL Mast....................................................1781 Disassemble.........................................................1781 Mast and Chains, Clean and Inspect..................................1785 Two-Stage LFL and Two-Stage FFL Mast, Assemble..........................1786 Three-Stage FFL Mast, Assemble..........................................1787 Install.................................................................1788 Lift Cylinders Repair.......................................................1790 Main Lift Cylinders, Remove.............................................1790 Free-Lift Cylinder, Remove..............................................1790 Cylinders, Disassemble..................................................1791 Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder........1791 Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder.........1793 Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift ....1793 Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift ....1794 Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas....1795 Clean and Inspect.......................................................1796 Cylinders, Assemble.....................................................1796 Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder........1796 Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder.........1797 Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift ....1798 Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift ....1799 Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas....1799 Main Lift Cylinders, Install............................................1800 Free-Lift Cylinder, Install.............................................1800 Header Hose Arrangements....................................................1801 Two-Stage LFL Mast, New Hose Install....................................1801 Two-Stage LFL Mast, Adjust Hoses After Installation.....................1806 Two-Stage FFL Mast, New Hose Install....................................1807 Two-Stage FFL Mast, Adjust Hoses After Installation.....................1813 Three-Stage FFL Mast, New Hose Install..................................1813 Three-Stage FFL Mast, Adjust Hoses After Installation...................1824 Header Hose Arrangement.....................................................1825 Two-Stage LFL Mast, New Hose Install....................................1825 Two-Stage LFL Mast, Adjust Hoses After Installation.....................1829 Two-Stage FFL Mast, New Hose Install....................................1830 Two-Stage FFL Mast, Adjust Hoses After Installation.....................1836 Three-Stage FFL Mast, New Hose Install..................................1836 Three-Stage FFL Mast, Adjust Hoses After Install........................1845 Lift and Tilt System Leak Check.............................................1846 Lift Cylinders Leak Check...............................................1846 Tilt Cylinders Leak Check...............................................1846 Tilt Cylinders Adjustment...................................................1847 Lift Chains Adjustment......................................................1849 Mast Adjustment.............................................................1851 Carriage Adjustment.........................................................1853 Troubleshooting.............................................................1854 tables..........................................................................1751 Table 1. Hook-Type Carriage Chain Adjustment................................1849 Table 2. Pin-Type Carriage Chain Adjustment.................................1850 PM (1)..............................................................................1857 toc.............................................................................1857 Periodic Maintenance........................................................1857 Safety Precautions Maintenance and Repair...................................1858 General.....................................................................1863 Serial Number Data......................................................1863 How to Move Disabled Lift Truck.........................................1863 How to Tow Lift Truck...............................................1863 How to Put Lift Truck on Blocks.........................................1864 How to Raise Drive Tires............................................1864 How to Raise Steering Tires.........................................1864 Maintenance Schedule........................................................1865 Maintenance Procedures Every 8 Hours or Daily...............................1873 How to Make Checks With Key OFF.........................................1873 Tires and Wheels....................................................1873 Forks...............................................................1874 Adjust..........................................................1874 Remove..........................................................1874 Install.........................................................1875 Forks, Mast, and Lift Chains, Inspect...............................1876 Safety Labels.......................................................1877 Steering Column Latch...............................................1877 Operator Restraint System...........................................1877 Battery Restraint System E1.50-3.20XM, E2.00XMS (E25-65XM, E25-6....1878 Battery Restraint System J2.00-3.20XM (J40-60XM and J40-60XM 2 )....1879 Battery.............................................................1880 Hydraulic System....................................................1881 How to Make Checks With Key ON..........................................1882 Gauges, Horn, and Fuses.............................................1882 Steering System.....................................................1882 Service Brakes......................................................1882 Parking Brake.......................................................1882 Control Levers and Pedals...........................................1883 Direction and Speed Control Pedals..................................1883 Lift System Operation...............................................1883 Maintenance Procedures Every 250 Hours or 6 Weeks...........................1883 Steering Tie Rods.......................................................1883 Steering King Pins, Trucks Only.........................................1883 Maintenance Procedures Every 500 Hours or 3 Months..........................1884 Hydraulic Tank Breather.................................................1884 Differential and Speed Reducer..........................................1884 Wheel Nut Torques.......................................................1885 Steering Axle Spindles..................................................1885 Steering Tie Rods.......................................................1885 Mast....................................................................1885 Lift Chains.............................................................1886 Wear Check..........................................................1886 Forks...................................................................1887 Brake Fluid.............................................................1887 Other Lubrication.......................................................1887 Seat Brake, Models E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM........1888 Electrical Inspection...................................................1888 Contactors..........................................................1888 Motor Brushes.......................................................1889 Motor Brushes, General..............................................1889 Maintenance Procedures Every 1000 Hours or 6 Months.........................1904 Lift Chains.............................................................1904 Forks...................................................................1904 Check Upper and Lower Bearings, Integral Sideshift Carriage.............1904 Maintenance Procedures Every 2000 Hours or Yearly...........................1905 Hydraulic System........................................................1905 Change Filter for Hydraulic Oil.....................................1905 Change Hydraulic Oil................................................1906 Differential and Speed Reducer..........................................1906 Service Brakes..........................................................1907 Contactors..............................................................1907 Wheel Bearings..........................................................1907 Steer Wheels, Lubrication...........................................1907 Drive Wheels, Lubrication...........................................1907 Lift Chains.............................................................1908 Replace Upper and Lower Bearings, Integral Sideshift Carriage...........1908 Steering Axle...........................................................1908 King Pins and Rod Ends (Steering Cylinders).........................1908 Other Lubrication.......................................................1908 Battery Maintenance.........................................................1908 How to Charge Battery...................................................1908 How to Change Battery...................................................1910 General.............................................................1910 Change Battery, E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM 2 ....1910 Change J2.00-3.20XM (J40-60XM and J40-60XM 2 ) Battery..............1913 Lift and Tilt System Leak Check.............................................1915 Lift Cylinders Leak Check...............................................1915 Tilt Cylinders Leak Check...............................................1915 Safety Procedures When Working Near Mast....................................1916 Lift Chain Adjustments......................................................1918 PMT Circuit Check...........................................................1919 Welding Repairs.............................................................1920 Overhead Guard Changes......................................................1920 Wheels and Tire Maintenance.................................................1921 Tires and Wheels, E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM ........1921 Remove Wheels From Lift Truck.......................................1921 Remove and Install Tire on Wheel....................................1921 Pneumatic Tires and Wheels J2.00-3.20XM (J40-60XM and J40-60XM 2........1922 Remove Wheels From Lift Truck.......................................1922 Remove Wheel From Pneumatic Tire....................................1923 Install Wheel in Pneumatic Tire.....................................1924 Install Three- or Four-Piece Wheel in Pneumatic Tire................1925 Add Air to Tires....................................................1926 Wheels, Install.....................................................1926 Solid Rubber Tires on Pneumatic Wheels..................................1927 Remove Wheels From Lift Truck.......................................1927 Remove Solid Rubber Tire From Pneumatic Wheel.......................1927 Install Solid Rubber Tire on Pneumatic Wheel........................1929 Wheels, Install.....................................................1930 Solid Rubber Tire, Change...............................................1930 Remove and Install Tire on Wheel....................................1930 Remove Wheel From Tire..............................................1932 Install Wheel in Tire...............................................1933 SIT Tire, Change........................................................1934 Remove SIT Solid Tire From Wheel....................................1935 Install SIT Solid Tire on Wheel.....................................1936 Adhesives and Sealants......................................................1937 tables..........................................................................1857 Table 1. Maintenance Schedule...............................................1867 PM..................................................................................1941 toc.............................................................................1941 Periodic Maintenance........................................................1941 Safety Precautions Maintenance and Repair...................................1942 General.....................................................................1947 Serial Number Data......................................................1947 How to Move Disabled Lift Truck.........................................1947 How to Tow Lift Truck...............................................1947 How to Put Lift Truck on Blocks.........................................1948 How to Raise Drive Tires............................................1948 How to Raise Steering Tires.........................................1948 Maintenance Schedule........................................................1949 Maintenance Procedures Every 8 Hours or Daily...............................1957 How to Make Checks With Key OFF.........................................1957 Tires and Wheels....................................................1957 Forks...............................................................1958 Adjust..........................................................1958 Remove..........................................................1958 Install.........................................................1959 Forks, Mast, and Lift Chains, Inspect...............................1960 Safety Labels.......................................................1961 Steering Column Latch...............................................1961 Operator Restraint System...........................................1961 Battery Restraint System E1.50-3.20XM, E2.00XMS (E25-65XM, E25-6....1962 Battery Restraint System J2.00-3.20XM (J40-60XM and J40-60XM 2 )....1963 Battery.............................................................1964 Hydraulic System....................................................1965 How to Make Checks With Key ON..........................................1966 Gauges, Horn, and Fuses.............................................1966 Steering System.....................................................1966 Service Brakes......................................................1966 Parking Brake.......................................................1966 Control Levers and Pedals...........................................1967 Direction and Speed Control Pedals..................................1967 Lift System Operation...............................................1967 Maintenance Procedures Every 250 Hours or 6 Weeks...........................1967 Steering Tie Rods.......................................................1967 Steering King Pins, Trucks Only.........................................1967 Maintenance Procedures Every 500 Hours or 3 Months..........................1968 Hydraulic Tank Breather.................................................1968 Differential and Speed Reducer..........................................1968 Wheel Nut Torques.......................................................1969 Steering Axle Spindles..................................................1969 Steering Tie Rods.......................................................1969 Mast....................................................................1969 Lift Chains.............................................................1970 Wear Check..........................................................1970 Forks...................................................................1971 Brake Fluid.............................................................1971 Other Lubrication.......................................................1971 Seat Brake, Models E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM........1972 Electrical Inspection...................................................1972 Contactors..........................................................1972 Motor Brushes.......................................................1973 Motor Brushes, General..............................................1973 Maintenance Procedures Every 1000 Hours or 6 Months.........................1988 Lift Chains.............................................................1988 Forks...................................................................1988 Check Upper and Lower Bearings, Integral Sideshift Carriage.............1988 Maintenance Procedures Every 2000 Hours or Yearly...........................1989 Hydraulic System........................................................1989 Change Filter for Hydraulic Oil.....................................1989 Change Hydraulic Oil................................................1990 Differential and Speed Reducer..........................................1990 Service Brakes..........................................................1991 Contactors..............................................................1991 Wheel Bearings..........................................................1991 Steer Wheels, Lubrication...........................................1991 Drive Wheels, Lubrication...........................................1991 Lift Chains.............................................................1992 Replace Upper and Lower Bearings, Integral Sideshift Carriage...........1992 Steering Axle...........................................................1992 King Pins and Rod Ends (Steering Cylinders).........................1992 Other Lubrication.......................................................1992 Battery Maintenance.........................................................1992 How to Charge Battery...................................................1992 How to Change Battery...................................................1994 General.............................................................1994 Change Battery, E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM 2 ....1994 Change J2.00-3.20XM (J40-60XM and J40-60XM 2 ) Battery..............1997 Lift and Tilt System Leak Check.............................................1999 Lift Cylinders Leak Check...............................................1999 Tilt Cylinders Leak Check...............................................1999 Safety Procedures When Working Near Mast....................................2000 Lift Chain Adjustments......................................................2002 PMT Circuit Check...........................................................2003 Welding Repairs.............................................................2004 Overhead Guard Changes......................................................2004 Wheels and Tire Maintenance.................................................2005 Tires and Wheels, E1.50-3.20XM, E2.00XMS (E25-65XM and E25-65XM ........2005 Remove Wheels From Lift Truck.......................................2005 Remove and Install Tire on Wheel....................................2005 Pneumatic Tires and Wheels J2.00-3.20XM (J40-60XM and J40-60XM 2........2006 Remove Wheels From Lift Truck.......................................2006 Remove Wheel From Pneumatic Tire....................................2007 Install Wheel in Pneumatic Tire.....................................2008 Install Three- or Four-Piece Wheel in Pneumatic Tire................2009 Add Air to Tires....................................................2010 Wheels, Install.....................................................2010 Solid Rubber Tires on Pneumatic Wheels..................................2011 Remove Wheels From Lift Truck.......................................2011 Remove Solid Rubber Tire From Pneumatic Wheel.......................2011 Install Solid Rubber Tire on Pneumatic Wheel........................2013 Wheels, Install.....................................................2014 Solid Rubber Tire, Change...............................................2014 Remove and Install Tire on Wheel....................................2014 Remove Wheel From Tire..............................................2016 Install Wheel in Tire...............................................2017 SIT Tire, Change........................................................2018 Remove SIT Solid Tire From Wheel....................................2019 Install SIT Solid Tire on Wheel.....................................2020 Adhesives and Sealants......................................................2021 tables..........................................................................1941 Table 1. Maintenance Schedule...............................................1951 SEM Diagrams (1)....................................................................2025 toc.............................................................................2025 Electrical Diagrams.........................................................2025 Safety Precautions Maintenance and Repair...................................2026 SEM Diagrams........................................................................2095 toc.............................................................................2095 Electrical Diagrams.........................................................2095 Safety Precautions Maintenance and Repair...................................2096 SEM Display (1).....................................................................2165 toc.............................................................................2165 SEM Display Panel...........................................................2165 Safety Precautions Maintenance and Repair...................................2166 General.....................................................................2169 SEM Display Panel Features..................................................2169 Common Features Descriptions............................................2172 LED Symbol Indicators...............................................2172 LCD Screen..........................................................2172 Battery Discharge Indicator (BDI)...................................2172 Service Reminder....................................................2172 Status Codes........................................................2172 Hourmeter...........................................................2172 Premium Display Panel Additional Features...............................2172 Additional Features Descriptions (Available With Premium Display........2173 LCD Screen..........................................................2173 Operator Passwords..................................................2173 Daily Check List and Service Items..................................2173 Performance Modes...................................................2173 Status Code Lists...................................................2173 BDI, Adjust.........................................................2174 SEM Display Panel Indicators................................................2174 All Indicator Symbols...................................................2174 Hourmeter Indicator Symbol..........................................2174 Wrench Indicator Symbol.............................................2174 Battery Indicator Symbol............................................2174 Battery State-of-Charge (BDI).......................................2174 Brake Fluid Low Symbol..............................................2174 Parking Brake Symbol................................................2174 Fasten Seat Belt Symbol.............................................2174 LCD Screen (Standard Display Panel).....................................2175 Premium Display Panel Additional Components.................................2175 Alpha Numerical Screen..................................................2175 STAR Push Button........................................................2175 Push Buttons ##1 Through ##5............................................2175 Computer Adjustments........................................................2175 Computer System.........................................................2175 Connect PC to SEM Display Panel.....................................2176 ITW Switches Software Program (for SEM Display Panel).......................2177 Description.............................................................2177 Where to Get Help.......................................................2177 Hardware and Software Requirements......................................2177 How to Start ITW Switches Program.......................................2178 Menus...................................................................2178 Create a Setup File.....................................................2184 SEM Display Panel Replacement...............................................2201 General.................................................................2201 Remove and Replace......................................................2201 tables..........................................................................2165 Table 1. Adapter Pins (DB25F to DB9)........................................2176 SEM Display.........................................................................2207 toc.............................................................................2207 SEM Display Panel...........................................................2207 Safety Precautions Maintenance and Repair...................................2208 General.....................................................................2211 SEM Display Panel Features..................................................2211 Common Features Descriptions............................................2214 LED Symbol Indicators...............................................2214 LCD Screen..........................................................2214 Battery Discharge Indicator (BDI)...................................2214 Service Reminder....................................................2214 Status Codes........................................................2214 Hourmeter...........................................................2214 Premium Display Panel Additional Features...............................2214 Additional Features Descriptions (Available With Premium Display........2215 LCD Screen..........................................................2215 Operator Passwords..................................................2215 Daily Check List and Service Items..................................2215 Performance Modes...................................................2215 Status Code Lists...................................................2215 BDI, Adjust.........................................................2216 SEM Display Panel Indicators................................................2216 All Indicator Symbols...................................................2216 Hourmeter Indicator Symbol..........................................2216 Wrench Indicator Symbol.............................................2216 Battery Indicator Symbol............................................2216 Battery State-of-Charge (BDI).......................................2216 Brake Fluid Low Symbol..............................................2216 Parking Brake Symbol................................................2216 Fasten Seat Belt Symbol.............................................2216 LCD Screen (Standard Display Panel).....................................2217 Premium Display Panel Additional Components.................................2217 Alpha Numerical Screen..................................................2217 STAR Push Button........................................................2217 Push Buttons ##1 Through ##5............................................2217 Computer Adjustments........................................................2217 Computer System.........................................................2217 Connect PC to SEM Display Panel.....................................2218 ITW Switches Software Program (for SEM Display Panel).......................2219 Description.............................................................2219 Where to Get Help.......................................................2219 Hardware and Software Requirements......................................2219 How to Start ITW Switches Program.......................................2220 Menus...................................................................2220 Create a Setup File.....................................................2226 SEM Display Panel Replacement...............................................2243 General.................................................................2243 Remove and Replace......................................................2243 tables..........................................................................2207 Table 1. Adapter Pins (DB25F to DB9)........................................2218 SEM Programming (1).................................................................2249 toc.............................................................................2249 Transistor Motor Controllers................................................2249 Safety Precautions Maintenance and Repair...................................2250 General.....................................................................2253 Function Numbers........................................................2253 Motor Controller Checks and Adjustments.....................................2254 Parameter Tables........................................................2254 tables..........................................................................2249 Table 1. SR (SEM) Register Parameters for Traction Motor Control............2254 Table 2. SR (SEM) Register Parameters for Traction Motor Control............2258 Table 3. SP Register Parameters for Pump Motor Controller - E1.5............2261 Table 4. SR (SEM) Register Parameters for Traction Motor Control............2265 Table 5. SR (SEM) Register Parameters for Traction Motor Control............2269 Table 6. SR (SEM) Register Parameters for Traction Motor Control............2272 Table 7. SR (SEM) Register Parameters for Traction Motor Control............2276 Table 8. SP Register Parameters for Pump Motor Controller - E45-............2279 Table 9. SP Register Parameters for Pump Motor Controller - E2.0............2283 Table 10. SR (SEM) Register Parameters for Traction Motor Contro............2287 Table 11. SR (SEM) Register Parameters for Traction Motor Contro............2290 Table 12. SR (SEM) Register Parameters for Traction Motor Contro............2293 Table 13. SP Register Parameters for Pump Motor Controller - J40............2296 Table 14. SP Register Parameters for Pump Motor Controller - J2.............2299 Table 15. SR (SEM) Register Parameters for Traction Motor Contro............2303 Table 16. SR (SEM) Register Parameters for Traction Motor Contro............2307 Table 17. SP Register Parameters for Pump Motor Controller - N30............2311 SEM Programming.....................................................................2317 toc.............................................................................2317 Transistor Motor Controllers................................................2317 Safety Precautions Maintenance and Repair...................................2318 General.....................................................................2321 Function Numbers........................................................2321 Motor Controller Checks and Adjustments.....................................2322 Parameter Tables........................................................2322 tables..........................................................................2317 Table 1. SR (SEM) Register Parameters for Traction Motor Control............2322 Table 2. SR (SEM) Register Parameters for Traction Motor Control............2326 Table 3. SP Register Parameters for Pump Motor Controller - E1.5............2329 Table 4. SR (SEM) Register Parameters for Traction Motor Control............2333 Table 5. SR (SEM) Register Parameters for Traction Motor Control............2337 Table 6. SR (SEM) Register Parameters for Traction Motor Control............2340 Table 7. SR (SEM) Register Parameters for Traction Motor Control............2344 Table 8. SP Register Parameters for Pump Motor Controller - E45-............2347 Table 9. SP Register Parameters for Pump Motor Controller - E2.0............2351 Table 10. SR (SEM) Register Parameters for Traction Motor Contro............2355 Table 11. SR (SEM) Register Parameters for Traction Motor Contro............2358 Table 12. SR (SEM) Register Parameters for Traction Motor Contro............2361 Table 13. SP Register Parameters for Pump Motor Controller - J40............2364 Table 14. SP Register Parameters for Pump Motor Controller - J2.............2367 Table 15. SR (SEM) Register Parameters for Traction Motor Contro............2371 Table 16. SR (SEM) Register Parameters for Traction Motor Contro............2375 Table 17. SP Register Parameters for Pump Motor Controller - N30............2379 SEM Troubleshooting (1).............................................................2385 toc.............................................................................2385 SR/SP Transistor Motor Controllers..........................................2385 Safety Precautions Maintenance and Repair...................................2386 Description.................................................................2391 General.................................................................2391 Model Number Data for SR/SP Transistor Motor Controllers................2392 Motor Controller Checks and Adjustments.....................................2395 Checks and Adjustments Using Handset........................................2395 General.................................................................2395 Connect Handset.........................................................2396 Start Sequence..........................................................2396 Check or Delete Stored Status Codes.....................................2397 Returning Lift Truck to Normal Operation................................2400 Workbench Checks and Adjustments........................................2400 How to Check and Adjust Registers.......................................2400 Function Parameters Adjustments.............................................2402 General.................................................................2402 Function Numbers........................................................2403 When Handset is Connected to Motor Controller in Lift Truck.............2403 Function Numbers 1 through 15.......................................2403 Function Numbers 16 through 30......................................2403 Function Numbers 48 through 63......................................2404 Function Number Descriptions................................................2405 Traction Motor Controller (Label Letter - SR)...............................2405 Function Number 01 AUTO REGEN ENABLE SPEED..............................2405 Function Number 02 CREEP SPEED..........................................2405 Function Number 03 CONTROLLED ACCELERATION..............................2405 Function Number 04 ARMATURE CURRENT LIMIT...............................2406 Function Number 05 REGEN RAMP RATE......................................2406 Function Number 06 FIELD WEAKENING (FW) RATIO...........................2406 Function Number 07 MINIMUM FIELD CURRENT................................2406 Function Number 08 MAXIMUM FIELD CURRENT................................2406 Function Number 09 REGENERATIVE BRAKING CURRENT LIMIT (C/L).............2406 Function Number 10 FIELD CURRENT FOR REGENERATIVE BRAKING...............2407 Function Number 12 MAXIMUM ARMATURE % ON TIME (Travel Speed Limi........2407 Function Number 13 SPEED LIMIT 3........................................2407 Function Number 14 INTERNAL RESISTANCE COMPENSATION.....................2407 Function Number 15 BATTERY VOLTAGE SELECTION............................2408 Function Number 16 STALL TRIP POINT % ON TIME...........................2408 Function Number 17 CONTROL TYPE SELECTION...............................2408 Function Number 18 STEERING PUMP TIME DELAY.............................2409 Function Number 19 MAINTENANCE CODE TENS AND UNITS......................2409 Function Number 20 MAINTENANCE CODE THOUSANDS AND HUNDREDS..............2409 Function Number 21 AUTO REGEN BRAKING CURRENT LIMIT.....................2409 Function Number 23 FOR SPECIAL FUNCTIONS................................2409 Function Number 24 FIELD WEAKENING START................................2409 Function Number 25 MONITOR..............................................2409 Function Number 26 BASE RATIO...........................................2410 Function Number 28 STORED STATUS CODE COUNT POINTER.....................2410 Functions with Premium Display Panel Only...............................2410 Function Number 48 MODE 1 - CONTROLLED ACCELERATION.................2410 Function Number 49 MODE 1 FIELD WEAKENING (FW) START................2411 Function Number 50 MODE 1 - FIELD WEAKENING (FW) RATIO..............2411 Function 51 MODE 1 - MAXIMUM ARMATURE % ON TIME (MODE 1 - TRAVEL....2411 Function 52 MODE 2 - CONTROLLED ACCELERATION........................2411 Function Number 53 MODE 2 - FIELD WEAKENING (FW) START..............2411 Function Number 54 MODE 2 - FIELD WEAKENING (FW) RATIO..............2411 Function Number 55 MODE 2 - MAXIMUM ARMATURE % ON TIME (MODE 2 -....2412 Function Number 56 MODE 3 - CONTROLLED ACCELERATION.................2412 Function Number 57 MODE 3 - FIELD WEAKENING (FW) START..............2412 Function Number 58 MODE 3 - FIELD WEAKENING (FW) RATIO..............2412 Function Number 59 MODE 3 - MAXIMUM ARMATURE % ON TIME (MODE 3 -....2412 Function Number 60 MODE 4 - CONTROLLED ACCELERATION.................2412 Function Number 61 MODE 4 - FIELD WEAKENING (FW) START..............2412 Function Number 62 MODE 4 - FIELD WEAKENING (FW) RATIO..............2413 Function Number 63 MODE 4 - MAXIMUM ARMATURE % ON TIME (MODE 4 -....2413 Pump Motor Controller (Label Letter - SP)...................................2413 Function Number 01 STORED STATUS CODE...................................2413 Function Number 02 INTERNAL RESISTANCE COMPENSATION START...............2413 Function Number 03 CONTROLLED ACCELERATION..............................2413 Function Number 04 CURRENT LIMIT........................................2414 Function Number 07 INTERNAL RESISTANCE COMPENSATION RATE................2414 Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and S........2414 Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lif........2414 Function Number 13 SPEED LIMIT 3 (SL3) Fast Lift........................2414 Function Number 16 SPEED/TORQUE COMPENSATION............................2414 Function Number 17 CONTROL TYPE SELECTION...............................2415 Function Numbers 18 through 27 TEMPORARY DATA REGISTERS.................2415 Function Number 28 STORED STATUS CODE COUNT POINTER.....................2415 Functions with Premium Display Panel Only...............................2415 Function Number 48 MODE 1 - CONTROLLED ACCELERATION.................2415 Function Number 49 MODE 1 - SPEED LIMIT 2...........................2416 Function Number 50 MODE 1 - SPEED LIMIT 3...........................2416 Function Number 52 MODE 2 - CONTROLLED ACCELERATION.................2416 Function Number 53 MODE 2 - SPEED LIMIT 2...........................2416 Function Number 54 MODE 2 - SPEED LIMIT 3...........................2416 Function Number 56 MODE 3 - CONTROLLED ACCELERATION.................2416 Function Number 57 MODE 3 - SPEED LIMIT 2...........................2416 Function Number 58 MODE 3 - SPEED LIMIT 3...........................2416 Function Number 60 MODE 4 - CONTROLLED ACCELERATION.................2417 Function Number 61 MODE 4 - SPEED LIMIT 2...........................2417 Function Number 62 MODE 4 - SPEED LIMIT 3...........................2417 Troubleshooting.............................................................2421 General.................................................................2421 Status Codes............................................................2422 SR (SEM) and SP Status Code Charts..........................................2425 SR/SP Transistor Motor Controller Repair....................................2460 General.................................................................2460 General Maintenance Instructions........................................2462 Special Precautions.................................................2462 Fuses...................................................................2463 Contactors..............................................................2463 Repair..............................................................2463 Contactor Driver Module.................................................2465 Contactor Driver, Replace...........................................2465 Motor Controller Plug...................................................2466 Brush Wear Indicators...................................................2470 Thermal Sensors.........................................................2470 Motor Controller, Replace...............................................2470 Theory of Operation.........................................................2471 General.................................................................2471 SEM System Description..................................................2472 SEM System Operation (SR Motor Controller)..............................2473 Reverse Circuit.....................................................2473 Performance and Efficiency..........................................2474 Field Weakening.....................................................2474 Regenerative Braking................................................2475 SEM System Operation (SP Motor Controller)..............................2475 Creep Speed.........................................................2475 Controlled Acceleration.............................................2475 Current Limit (CL)..................................................2475 Braking.................................................................2475 Regenerative Braking to Zero Speed..................................2475 Pedal Position Braking..............................................2476 Auto Braking........................................................2476 Auxiliary Speed Control.................................................2476 Field Weakening.....................................................2476 Speed Limits........................................................2476 Ramp Operation..........................................................2476 Ramp Start..........................................................2476 Anti-rollback.......................................................2476 Steer Pump Contactor Time Delay.........................................2476 Coil Drivers and Internal Coil Suppression..............................2476 System Protective Override..............................................2477 Static Return to Off (SRO)..........................................2477 Accelerator Volts Hold Off..........................................2477 Pulse Monitor Trip (PMT)............................................2477 Thermal Protector (TP)..............................................2477 Low Voltage.........................................................2477 SP Pump Motor Controllers...............................................2477 Contactor Driver Module.................................................2478 Diagnostics.............................................................2478 Systems Diagnostics.................................................2478 Standard Status Codes...............................................2478 Stored Status Codes.................................................2478 Hourmeter Readings..................................................2478 Maintenance Management Capability...................................2479 tables..........................................................................2385 Table 1. List of Status Codes...............................................2398 Table 2. Speed/Torque Compensation..........................................2414 Table 3. Function Map for Motor Controllers SR (Traction)...................2417 Table 4. Function Map for Motor Controller SP (Lift Pump Motor).............2420 Table 5. List of Status Codes...............................................2423 Table 6. Large (P) Plug (23-Pin) Connections/Descriptions for Mo............2466 Table 7. Small Plug (12-Pin) Connections/Descriptions for Motor ............2467 SEM Troubleshooting.................................................................2483 toc.............................................................................2483 SR/SP Transistor Motor Controllers..........................................2483 Safety Precautions Maintenance and Repair...................................2484 Description.................................................................2489 General.................................................................2489 Model Number Data for SR/SP Transistor Motor Controllers................2490 Motor Controller Checks and Adjustments.....................................2493 Checks and Adjustments Using Handset........................................2493 General.................................................................2493 Connect Handset.........................................................2494 Start Sequence..........................................................2494 Check or Delete Stored Status Codes.....................................2495 Returning Lift Truck to Normal Operation................................2498 Workbench Checks and Adjustments........................................2498 How to Check and Adjust Registers.......................................2498 Function Parameters Adjustments.............................................2500 General.................................................................2500 Function Numbers........................................................2501 When Handset is Connected to Motor Controller in Lift Truck.............2501 Function Numbers 1 through 15.......................................2501 Function Numbers 16 through 30......................................2501 Function Numbers 48 through 63......................................2502 Function Number Descriptions................................................2503 Traction Motor Controller (Label Letter - SR)...............................2503 Function Number 01 AUTO REGEN ENABLE SPEED..............................2503 Function Number 02 CREEP SPEED..........................................2503 Function Number 03 CONTROLLED ACCELERATION..............................2503 Function Number 04 ARMATURE CURRENT LIMIT...............................2504 Function Number 05 REGEN RAMP RATE......................................2504 Function Number 06 FIELD WEAKENING (FW) RATIO...........................2504 Function Number 07 MINIMUM FIELD CURRENT................................2504 Function Number 08 MAXIMUM FIELD CURRENT................................2504 Function Number 09 REGENERATIVE BRAKING CURRENT LIMIT (C/L).............2504 Function Number 10 FIELD CURRENT FOR REGENERATIVE BRAKING...............2505 Function Number 12 MAXIMUM ARMATURE % ON TIME (Travel Speed Limi........2505 Function Number 13 SPEED LIMIT 3........................................2505 Function Number 14 INTERNAL RESISTANCE COMPENSATION.....................2505 Function Number 15 BATTERY VOLTAGE SELECTION............................2506 Function Number 16 STALL TRIP POINT % ON TIME...........................2506 Function Number 17 CONTROL TYPE SELECTION...............................2506 Function Number 18 STEERING PUMP TIME DELAY.............................2507 Function Number 19 MAINTENANCE CODE TENS AND UNITS......................2507 Function Number 20 MAINTENANCE CODE THOUSANDS AND HUNDREDS..............2507 Function Number 21 AUTO REGEN BRAKING CURRENT LIMIT.....................2507 Function Number 23 FOR SPECIAL FUNCTIONS................................2507 Function Number 24 FIELD WEAKENING START................................2507 Function Number 25 MONITOR..............................................2507 Function Number 26 BASE RATIO...........................................2508 Function Number 28 STORED STATUS CODE COUNT POINTER.....................2508 Functions with Premium Display Panel Only...............................2508 Function Number 48 MODE 1 - CONTROLLED ACCELERATION.................2508 Function Number 49 MODE 1 FIELD WEAKENING (FW) START................2509 Function Number 50 MODE 1 - FIELD WEAKENING (FW) RATIO..............2509 Function 51 MODE 1 - MAXIMUM ARMATURE % ON TIME (MODE 1 - TRAVEL....2509 Function 52 MODE 2 - CONTROLLED ACCELERATION........................2509 Function Number 53 MODE 2 - FIELD WEAKENING (FW) START..............2509 Function Number 54 MODE 2 - FIELD WEAKENING (FW) RATIO..............2509 Function Number 55 MODE 2 - MAXIMUM ARMATURE % ON TIME (MODE 2 -....2510 Function Number 56 MODE 3 - CONTROLLED ACCELERATION.................2510 Function Number 57 MODE 3 - FIELD WEAKENING (FW) START..............2510 Function Number 58 MODE 3 - FIELD WEAKENING (FW) RATIO..............2510 Function Number 59 MODE 3 - MAXIMUM ARMATURE % ON TIME (MODE 3 -....2510 Function Number 60 MODE 4 - CONTROLLED ACCELERATION.................2510 Function Number 61 MODE 4 - FIELD WEAKENING (FW) START..............2510 Function Number 62 MODE 4 - FIELD WEAKENING (FW) RATIO..............2511 Function Number 63 MODE 4 - MAXIMUM ARMATURE % ON TIME (MODE 4 -....2511 Pump Motor Controller (Label Letter - SP)...................................2511 Function Number 01 STORED STATUS CODE...................................2511 Function Number 02 INTERNAL RESISTANCE COMPENSATION START...............2511 Function Number 03 CONTROLLED ACCELERATION..............................2511 Function Number 04 CURRENT LIMIT........................................2512 Function Number 07 INTERNAL RESISTANCE COMPENSATION RATE................2512 Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and S........2512 Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lif........2512 Function Number 13 SPEED LIMIT 3 (SL3) Fast Lift........................2512 Function Number 16 SPEED/TORQUE COMPENSATION............................2512 Function Number 17 CONTROL TYPE SELECTION...............................2513 Function Numbers 18 through 27 TEMPORARY DATA REGISTERS.................2513 Function Number 28 STORED STATUS CODE COUNT POINTER.....................2513 Functions with Premium Display Panel Only...............................2513 Function Number 48 MODE 1 - CONTROLLED ACCELERATION.................2513 Function Number 49 MODE 1 - SPEED LIMIT 2...........................2514 Function Number 50 MODE 1 - SPEED LIMIT 3...........................2514 Function Number 52 MODE 2 - CONTROLLED ACCELERATION.................2514 Function Number 53 MODE 2 - SPEED LIMIT 2...........................2514 Function Number 54 MODE 2 - SPEED LIMIT 3...........................2514 Function Number 56 MODE 3 - CONTROLLED ACCELERATION.................2514 Function Number 57 MODE 3 - SPEED LIMIT 2...........................2514 Function Number 58 MODE 3 - SPEED LIMIT 3...........................2514 Function Number 60 MODE 4 - CONTROLLED ACCELERATION.................2515 Function Number 61 MODE 4 - SPEED LIMIT 2...........................2515 Function Number 62 MODE 4 - SPEED LIMIT 3...........................2515 Troubleshooting.............................................................2519 General.................................................................2519 Status Codes............................................................2520 SR (SEM) and SP Status Code Charts..........................................2523 SR/SP Transistor Motor Controller Repair....................................2558 General.................................................................2558 General Maintenance Instructions........................................2560 Special Precautions.................................................2560 Fuses...................................................................2561 Contactors..............................................................2561 Repair..............................................................2561 Contactor Driver Module.................................................2563 Contactor Driver, Replace...........................................2563 Motor Controller Plug...................................................2564 Brush Wear Indicators...................................................2568 Thermal Sensors.........................................................2568 Motor Controller, Replace...............................................2568 Theory of Operation.........................................................2569 General.................................................................2569 SEM System Description..................................................2570 SEM System Operation (SR Motor Controller)..............................2571 Reverse Circuit.....................................................2571 Performance and Efficiency..........................................2572 Field Weakening.....................................................2572 Regenerative Braking................................................2573 SEM System Operation (SP Motor Controller)..............................2573 Creep Speed.........................................................2573 Controlled Acceleration.............................................2573 Current Limit (CL)..................................................2573 Braking.................................................................2573 Regenerative Braking to Zero Speed..................................2573 Pedal Position Braking..............................................2574 Auto Braking........................................................2574 Auxiliary Speed Control.................................................2574 Field Weakening.....................................................2574 Speed Limits........................................................2574 Ramp Operation..........................................................2574 Ramp Start..........................................................2574 Anti-rollback.......................................................2574 Steer Pump Contactor Time Delay.........................................2574 Coil Drivers and Internal Coil Suppression..............................2574 System Protective Override..............................................2575 Static Return to Off (SRO)..........................................2575 Accelerator Volts Hold Off..........................................2575 Pulse Monitor Trip (PMT)............................................2575 Thermal Protector (TP)..............................................2575 Low Voltage.........................................................2575 SP Pump Motor Controllers...............................................2575 Contactor Driver Module.................................................2576 Diagnostics.............................................................2576 Systems Diagnostics.................................................2576 Standard Status Codes...............................................2576 Stored Status Codes.................................................2576 Hourmeter Readings..................................................2576 Maintenance Management Capability...................................2577 tables..........................................................................2483 Table 1. List of Status Codes...............................................2496 Table 2. Speed/Torque Compensation..........................................2512 Table 3. Function Map for Motor Controllers SR (Traction)...................2515 Table 4. Function Map for Motor Controller SP (Lift Pump Motor).............2518 Table 5. List of Status Codes...............................................2521 Table 6. Large (P) Plug (23-Pin) Connections/Descriptions for Mo............2564 Table 7. Small Plug (12-Pin) Connections/Descriptions for Motor ............2565 SEM WPC (1).........................................................................2581 toc.............................................................................2581 Display Panel for SEM Controls..............................................2581 Safety Precautions Maintenance and Repair...................................2582 General.....................................................................2585 SEM Display Panel Features..................................................2585 Descriptions of Common Features.........................................2585 LED Symbol Indicators...............................................2585 LCD Screen..........................................................2585 Battery Discharge Indicator (BDI)...................................2586 Service Reminder....................................................2586 Status Codes........................................................2586 Hourmeter...........................................................2586 Additional Features of Premium Display Panel............................2586 Descriptions of Additional Features (Available With Premium Disp........2586 LCD Screen..........................................................2586 Operator Passwords..................................................2587 Daily Check List and Service Items..................................2587 Performance Modes...................................................2587 Status Code Lists...................................................2587 Adjustment of BDI...................................................2587 SEM Display Panel Indicators................................................2588 All Indicator Symbols...................................................2588 Hourmeter Indicator Symbol..............................................2588 Wrench Indicator Symbol.................................................2588 Battery Indicator Symbol................................................2588 Battery State-of-Charge (BDI)...........................................2588 Brake Fluid Too Low Symbol..............................................2589 Parking Brake Symbol....................................................2589 Fasten Seat Belt Symbol.................................................2589 LCD Screen (Standard Display Panel).....................................2590 Additional Components of Premium Display Panel..............................2590 Alphanumeric Screen.....................................................2590 STAR Push Button........................................................2590 Push Buttons 1 Through 5................................................2590 Adjustments With a Computer.................................................2590 Computer System.........................................................2590 Connect PC to SEM Display Panel.....................................2591 ITW Switches Windows Software Program (for SEM Display Panel)...........2592 Description.........................................................2592 Getting Help........................................................2592 Hardware and Software Requirements..................................2592 Install.............................................................2592 How to Start ITW Switches Program...................................2592 Menus...............................................................2596 Sample Sessions.....................................................2605 Replacement.................................................................2627 SEM Display Panel.......................................................2627 Remove and Replace..................................................2627 tables..........................................................................2581 Table 1. Adapter Pins (DB25F to DB9)........................................2591 SEM WPC.............................................................................2633 toc.............................................................................2633 Display Panel for SEM Controls..............................................2633 Safety Precautions Maintenance and Repair...................................2634 General.....................................................................2637 SEM Display Panel Features..................................................2637 Descriptions of Common Features.........................................2637 LED Symbol Indicators...............................................2637 LCD Screen..........................................................2637 Battery Discharge Indicator (BDI)...................................2638 Service Reminder....................................................2638 Status Codes........................................................2638 Hourmeter...........................................................2638 Additional Features of Premium Display Panel............................2638 Descriptions of Additional Features (Available With Premium Disp........2638 LCD Screen..........................................................2638 Operator Passwords..................................................2639 Daily Check List and Service Items..................................2639 Performance Modes...................................................2639 Status Code Lists...................................................2639 Adjustment of BDI...................................................2639 SEM Display Panel Indicators................................................2640 All Indicator Symbols...................................................2640 Hourmeter Indicator Symbol..............................................2640 Wrench Indicator Symbol.................................................2640 Battery Indicator Symbol................................................2640 Battery State-of-Charge (BDI)...........................................2640 Brake Fluid Too Low Symbol..............................................2641 Parking Brake Symbol....................................................2641 Fasten Seat Belt Symbol.................................................2641 LCD Screen (Standard Display Panel).....................................2642 Additional Components of Premium Display Panel..............................2642 Alphanumeric Screen.....................................................2642 STAR Push Button........................................................2642 Push Buttons 1 Through 5................................................2642 Adjustments With a Computer.................................................2642 Computer System.........................................................2642 Connect PC to SEM Display Panel.....................................2643 ITW Switches Windows Software Program (for SEM Display Panel)...........2644 Description.........................................................2644 Getting Help........................................................2644 Hardware and Software Requirements..................................2644 Install.............................................................2644 How to Start ITW Switches Program...................................2644 Menus...............................................................2648 Sample Sessions.....................................................2657 Replacement.................................................................2679 SEM Display Panel.......................................................2679 Remove and Replace..................................................2679 tables..........................................................................2633 Table 1. Adapter Pins (DB25F to DB9)........................................2643 Specs (1)...........................................................................2685 toc.............................................................................2685 Capacities and Specifications...............................................2685 Safety Precautions Maintenance and Repair...................................2686 Counterweights..............................................................2689 Hydraulic System............................................................2689 Wheels and Tires............................................................2690 Battery Specifications......................................................2691 E2.00-3.20XM (E45-65XM, E45-65XM 2, N30XMH, N30XMH 2 )..................2691 J2.00-3.20XM (J40-65XM, J40-65XM 2 )....................................2692 Capacities..................................................................2693 Movement Rates (Maximum) for Tilt Cylinders.................................2693 Mast Speeds.................................................................2694 E45-65XM Mast Speeds (36 or 48 Volt) Americas...........................2694 E40-65XM, E40-65XM 2, N30XMH 2 Mast Speeds (36 or 48 Volt) Ameri........2700 E2.00-3.20XM Mast Speeds (72 or 80 Volt) Europe.........................2705 E2.00-3.20XM, E2.00-3.20XM 2 Mast Speeds (72 or 80 Volt) Europe.........2711 J40-65XM Mast Speeds (36 or 48 Volt) Americas...........................2714 J40-65XM, J40-65XM 2 Mast Speeds (36 or 48 Volt) Americas...............2718 J2.00-3.20XM Mast Speeds (72 or 80 Volt) Europe.........................2721 Torque Specifications.......................................................2729 Frame...................................................................2729 Drive Axle, Speed Reducer, and Differential E.200-3.20XM (E45-65........2729 Drive Axle, Speed Reducer, and Differential J2.00-3.20XM (J40-65........2729 Steering Axle E2.00-3.20XM (E45-65XM, E45-65XM 2 and N30XMH, N30........2730 Steering Axle J2.00-3.20XM (J40-65XM, J40-65XM 2 )......................2730 Masts...................................................................2730 Seat Brake..............................................................2730 Adhesives and Sealants......................................................2731 Specs...............................................................................2735 toc.............................................................................2735 Capacities and Specifications...............................................2735 Safety Precautions Maintenance and Repair...................................2736 Counterweights..............................................................2739 Hydraulic System............................................................2739 Wheels and Tires............................................................2740 Battery Specifications......................................................2741 E2.00-3.20XM (E45-65XM, E45-65XM 2, N30XMH, N30XMH 2 )..................2741 J2.00-3.20XM (J40-65XM, J40-65XM 2 )....................................2742 Capacities..................................................................2743 Movement Rates (Maximum) for Tilt Cylinders.................................2743 Mast Speeds.................................................................2744 E45-65XM Mast Speeds (36 or 48 Volt) Americas...........................2744 E40-65XM, E40-65XM 2, N30XMH 2 Mast Speeds (36 or 48 Volt) Ameri........2750 E2.00-3.20XM Mast Speeds (72 or 80 Volt) Europe.........................2755 E2.00-3.20XM, E2.00-3.20XM 2 Mast Speeds (72 or 80 Volt) Europe.........2761 J40-65XM Mast Speeds (36 or 48 Volt) Americas...........................2764 J40-65XM, J40-65XM 2 Mast Speeds (36 or 48 Volt) Americas...............2768 J2.00-3.20XM Mast Speeds (72 or 80 Volt) Europe.........................2771 Torque Specifications.......................................................2779 Frame...................................................................2779 Drive Axle, Speed Reducer, and Differential E.200-3.20XM (E45-65........2779 Drive Axle, Speed Reducer, and Differential J2.00-3.20XM (J40-65........2779 Steering Axle E2.00-3.20XM (E45-65XM, E45-65XM 2 and N30XMH, N30........2780 Steering Axle J2.00-3.20XM (J40-65XM, J40-65XM 2 )......................2780 Masts...................................................................2780 Seat Brake..............................................................2780 Adhesives and Sealants......................................................2781 Steer Axle (1)......................................................................2785 toc.............................................................................2785 Steering Axle...............................................................2785 Safety Precautions Maintenance and Repair...................................2786 General.....................................................................2789 Description.................................................................2789 Steering Axle Assembly Replacement..........................................2791 Remove..................................................................2791 Install.................................................................2791 Wheels Repair...............................................................2792 Remove and Disassemble..................................................2792 Clean...................................................................2792 Inspect.................................................................2792 Assemble and Install....................................................2792 Spindles, Bearings, and Tie Rods Repair.....................................2794 Remove and Disassemble..................................................2794 Assemble and Install....................................................2795 Steering Cylinder Repair....................................................2796 Remove and Disassemble..................................................2796 Clean and Inspect.......................................................2796 Assemble and Install....................................................2797 Torque Specifications.......................................................2797 Troubleshooting.............................................................2798 Steer Axle..........................................................................2801 toc.............................................................................2801 Steering Axle...............................................................2801 Safety Precautions Maintenance and Repair...................................2802 General.....................................................................2805 Description.................................................................2805 Steering Axle Assembly Replacement..........................................2807 Remove..................................................................2807 Install.................................................................2807 Wheels Repair...............................................................2808 Remove and Disassemble..................................................2808 Clean...................................................................2808 Inspect.................................................................2808 Assemble and Install....................................................2808 Spindles, Bearings, and Tie Rods Repair.....................................2810 Remove and Disassemble..................................................2810 Assemble and Install....................................................2811 Steering Cylinder Repair....................................................2812 Remove and Disassemble..................................................2812 Clean and Inspect.......................................................2812 Assemble and Install....................................................2813 Torque Specifications.......................................................2813 Troubleshooting.............................................................2814 Steer Housing (1)...................................................................2817 toc.............................................................................2817 Steering Housing and Control Unit...........................................2817 Safety Precautions Maintenance and Repair...................................2818 General.....................................................................2821 Description.................................................................2821 Operation...................................................................2822 Steering Wheel and Column Assembly Repair...................................2823 Steering Column Assembly, Remove........................................2823 Steering Control Unit...............................................2828 Disassemble.....................................................2828 Clean...........................................................2831 Assemble........................................................2832 Install.........................................................2839 Steering Column Assembly, Install.......................................2841 System Air Removal..........................................................2842 Remove..................................................................2842 Troubleshooting.............................................................2842 Steer Housing.......................................................................2847 toc.............................................................................2847 Steering Housing and Control Unit...........................................2847 Safety Precautions Maintenance and Repair...................................2848 General.....................................................................2851 Description.................................................................2851 Operation...................................................................2852 Steering Wheel and Column Assembly Repair...................................2853 Steering Column Assembly, Remove........................................2853 Steering Control Unit...............................................2858 Disassemble.....................................................2858 Clean...........................................................2861 Assemble........................................................2862 Install.........................................................2869 Steering Column Assembly, Install.......................................2871 System Air Removal..........................................................2872 Remove..................................................................2872 Troubleshooting.............................................................2872 Steering System (1).................................................................2877 toc.............................................................................2877 Steering System for Electric Lift Trucks....................................2877 Safety Precautions Maintenance and Repair...................................2878 General.....................................................................2881 Description.................................................................2883 Steering Wheel and Column Assembly Repair...................................2884 Assembly Components, Remove.............................................2884 Assembly Components, Install............................................2889 Power Steering Motor and Pump...............................................2892 Description.............................................................2892 Remove and Disassemble, Models E1.25-3.00XL (E25-60XL), J2.00-3.........2894 Remove and Disassemble, Models E3.50-5.50XL (E70-120XL, E70-120X........2897 Remove and Disassemble, Models J2.00-3.20XM (J40-60XM, J40-60XM ........2898 Remove and Disassemble, Models A1.00-1.50XL (A20-30XL)..................2899 Remove and Disassemble, Models E1.50-2.00XMS (E25-40XMS, E25-40X........2899 Assemble and Install - All models with a vertical mount except J........2900 Assemble and Install, Models J2.00-3.20XM (J40-60XM, J40-60XM 2 ........2900 Assemble and Install, Models E1.50-2.00XMS (E25-40XMS, E25-40XM ........2901 Power Steering Pump, Repair.............................................2901 Seal, Replace.......................................................2903 Hydraulic Steering Motor....................................................2903 Description.............................................................2903 Hydraulic Steering Motor Repairs........................................2904 Remove..............................................................2904 Disassemble.........................................................2904 Clean and Inspect...................................................2906 Assemble............................................................2906 Install.............................................................2907 Steering System Air Removal.................................................2907 Steering Pressure Check.....................................................2907 Steering Chain Tension Check (Unit With MDU Only)...........................2908 Optical Encoder and Activator Circuits Check................................2909 Troubleshooting.............................................................2911 Steering System.....................................................................2915 toc.............................................................................2915 Steering System for Electric Lift Trucks....................................2915 Safety Precautions Maintenance and Repair...................................2916 General.....................................................................2919 Description.................................................................2921 Steering Wheel and Column Assembly Repair...................................2922 Assembly Components, Remove.............................................2922 Assembly Components, Install............................................2927 Power Steering Motor and Pump...............................................2930 Description.............................................................2930 Remove and Disassemble, Models E1.25-3.00XL (E25-60XL), J2.00-3.........2932 Remove and Disassemble, Models E3.50-5.50XL (E70-120XL, E70-120X........2935 Remove and Disassemble, Models J2.00-3.20XM (J40-60XM, J40-60XM ........2936 Remove and Disassemble, Models A1.00-1.50XL (A20-30XL)..................2937 Remove and Disassemble, Models E1.50-2.00XMS (E25-40XMS, E25-40X........2937 Assemble and Install - All models with a vertical mount except J........2938 Assemble and Install, Models J2.00-3.20XM (J40-60XM, J40-60XM 2 ........2938 Assemble and Install, Models E1.50-2.00XMS (E25-40XMS, E25-40XM ........2939 Power Steering Pump, Repair.............................................2939 Seal, Replace.......................................................2941 Hydraulic Steering Motor....................................................2941 Description.............................................................2941 Hydraulic Steering Motor Repairs........................................2942 Remove..............................................................2942 Disassemble.........................................................2942 Clean and Inspect...................................................2944 Assemble............................................................2944 Install.............................................................2945 Steering System Air Removal.................................................2945 Steering Pressure Check.....................................................2945 Steering Chain Tension Check (Unit With MDU Only)...........................2946 Optical Encoder and Activator Circuits Check................................2947 Troubleshooting.............................................................2949 Tillt Cyl. (1)......................................................................2953 toc.............................................................................2953 Tilt Cylinders..............................................................2953 Safety Precautions Maintenance and Repair...................................2954 General.....................................................................2957 Description.................................................................2957 Tilt Cylinder Repair........................................................2957 Remove..................................................................2957 Disassemble.............................................................2957 Clean...................................................................2957 Assemble................................................................2957 Tilt Cylinders With O-Ring or Single-Lip Seals......................2957 Tilt Cylinders for XM and XMS Models................................2959 Tilt Cylinders for XL, XLS, and XL 3 Models.........................2960 Tilt Cylinders for H700-800A and Early Model H700-920B..............2962 Install.................................................................2963 Tilt Cylinders Using Chevron Packing................................2963 Install.........................................................2964 Tilt Cylinder Leak Check....................................................2966 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.........................2968 Torque Specifications.......................................................2968 Piston Rod Nut..........................................................2968 Retainer................................................................2969 Troubleshooting.............................................................2971 tables..........................................................................2953 Table 1. Movement Rates (Maximum) for Tilt Cylinders........................2967 Tillt Cyl...........................................................................2975 toc.............................................................................2975 Tilt Cylinders..............................................................2975 Safety Precautions Maintenance and Repair...................................2976 General.....................................................................2979 Description.................................................................2979 Tilt Cylinder Repair........................................................2979 Remove..................................................................2979 Disassemble.............................................................2979 Clean...................................................................2979 Assemble................................................................2979 Tilt Cylinders With O-Ring or Single-Lip Seals......................2979 Tilt Cylinders for XM and XMS Models................................2981 Tilt Cylinders for XL, XLS, and XL 3 Models.........................2982 Tilt Cylinders for H700-800A and Early Model H700-920B..............2984 Install.................................................................2985 Tilt Cylinders Using Chevron Packing................................2985 Install.........................................................2986 Tilt Cylinder Leak Check....................................................2988 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.........................2990 Torque Specifications.......................................................2990 Piston Rod Nut..........................................................2990 Retainer................................................................2991 Troubleshooting.............................................................2993 tables..........................................................................2975 Table 1. Movement Rates (Maximum) for Tilt Cylinders........................2989 Troubleshooting WPC (1).............................................................2997 ................................................................................2997 ................................................................................2998 ................................................................................2999 ................................................................................3000 ................................................................................3001 ................................................................................3002 ................................................................................3003 ................................................................................3004 ................................................................................3005 ................................................................................3006 ................................................................................3007 ................................................................................3008 ................................................................................3009 ................................................................................3010 ................................................................................3011 ................................................................................3012 ................................................................................3013 ................................................................................3014 ................................................................................3015 ................................................................................3016 Troubleshooting WPC.................................................................3017 ................................................................................3017 ................................................................................3018 ................................................................................3019 ................................................................................3020 ................................................................................3021 ................................................................................3022 ................................................................................3023 ................................................................................3024 ................................................................................3025 ................................................................................3026 ................................................................................3027 ................................................................................3028 ................................................................................3029 ................................................................................3030 ................................................................................3031 ................................................................................3032 ................................................................................3033 ................................................................................3034 ................................................................................3035 ................................................................................3036
HYSTER F108V (E60XM2-33) SERVICE MANUAL – PDF DOWNLOAD:
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