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Hyster H160 (J34XMT2) Service Manual – PDF DOWNLOAD
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Hyster H160 (J34XMT2) Service Manual – PDF DOWNLOAD
PART NO. 897658
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Hyster H160 (J34XMT2) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster H160 (J34XMT2) Service Manual – PDF DOWNLOAD
PART NO. 897658
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 H160 (J34XMT2) Service Manual – PDF DOWNLOAD
Brake System (1)................................................................ 1 toc......................................................................... 1 Brake System............................................................ 1 Safety Precautions Maintenance and Repair............................... 2 General................................................................. 5 Description............................................................. 5 Service Brake Pads Repair............................................... 5 Remove.............................................................. 5 Install............................................................. 5 Service Brake Caliper Repair............................................ 7 Remove.............................................................. 7 Install............................................................. 8 Disassemble......................................................... 8 Assemble............................................................ 8 Park Brake Caliper Repair............................................... 9 Remove.............................................................. 9 Install............................................................. 9 Disassemble......................................................... 10 Assemble............................................................ 10 Master Cylinder Repair.................................................. 10 Remove.............................................................. 10 Install............................................................. 11 Disassemble......................................................... 11 Assemble............................................................ 12 Foot-Operated Park Brake Lever Assembly Repair.......................... 12 Remove.............................................................. 12 Install............................................................. 13 Electrically Released Park Brake Repair................................. 15 Mechanical Operation................................................ 15 Remove.............................................................. 15 Install............................................................. 18 Electrically Released Park Brake - Electrical Components Repair......... 19 Control Box......................................................... 19 Remove.......................................................... 19 Install......................................................... 19 Terminal Block...................................................... 21 Remove.......................................................... 21 Install......................................................... 21 Park Brake Adjustment................................................... 23 Service Brake Adjustment................................................ 24 Brake System Air Removal................................................ 24 Troubleshooting......................................................... 25 Brake System.................................................................... 29 toc......................................................................... 29 Brake System............................................................ 29 Safety Precautions Maintenance and Repair............................... 30 General................................................................. 33 Description............................................................. 33 Service Brake Pads Repair............................................... 33 Remove.............................................................. 33 Install............................................................. 33 Service Brake Caliper Repair............................................ 35 Remove.............................................................. 35 Install............................................................. 36 Disassemble......................................................... 36 Assemble............................................................ 36 Park Brake Caliper Repair............................................... 37 Remove.............................................................. 37 Install............................................................. 37 Disassemble......................................................... 38 Assemble............................................................ 38 Master Cylinder Repair.................................................. 38 Remove.............................................................. 38 Install............................................................. 39 Disassemble......................................................... 39 Assemble............................................................ 40 Foot-Operated Park Brake Lever Assembly Repair.......................... 40 Remove.............................................................. 40 Install............................................................. 41 Electrically Released Park Brake Repair................................. 43 Mechanical Operation................................................ 43 Remove.............................................................. 43 Install............................................................. 46 Electrically Released Park Brake - Electrical Components Repair......... 47 Control Box......................................................... 47 Remove.......................................................... 47 Install......................................................... 47 Terminal Block...................................................... 49 Remove.......................................................... 49 Install......................................................... 49 Park Brake Adjustment................................................... 51 Service Brake Adjustment................................................ 52 Brake System Air Removal................................................ 52 Troubleshooting......................................................... 53 Control valve (1)............................................................... 57 toc......................................................................... 57 Main Control Valve...................................................... 57 Safety Precautions Maintenance and Repair............................... 58 General................................................................. 61 Description............................................................. 61 Operation............................................................... 62 Lift Section........................................................ 63 Tilt Section........................................................ 63 Tilt Backward................................................... 63 Tilt Forward.................................................... 63 Relief Valve........................................................ 63 Main Control Valve Repair............................................... 64 Remove.............................................................. 64 Install............................................................. 64 Disassemble......................................................... 65 Clean and Inspect................................................... 67 Assemble............................................................ 71 Relief Valve Check...................................................... 71 Vane Settings Adjustment................................................ 72 Mast Tilt Adjustment.................................................... 72 Troubleshooting......................................................... 73 Control valve................................................................... 79 toc......................................................................... 79 Main Control Valve...................................................... 79 Safety Precautions Maintenance and Repair............................... 80 General................................................................. 83 Description............................................................. 83 Operation............................................................... 84 Lift Section........................................................ 85 Tilt Section........................................................ 85 Tilt Backward................................................... 85 Tilt Forward.................................................... 85 Relief Valve........................................................ 85 Main Control Valve Repair............................................... 86 Remove.............................................................. 86 Install............................................................. 86 Disassemble......................................................... 87 Clean and Inspect................................................... 89 Assemble............................................................ 93 Relief Valve Check...................................................... 93 Vane Settings Adjustment................................................ 94 Mast Tilt Adjustment.................................................... 94 Troubleshooting......................................................... 95 Diagrams (1).................................................................... 101 toc......................................................................... 101 Diagrams................................................................ 101 Safety Precautions Maintenance and Repair............................... 102 Diagrams........................................................................ 135 toc......................................................................... 135 Diagrams................................................................ 135 Safety Precautions Maintenance and Repair............................... 136 Electrical System (1)........................................................... 169 toc......................................................................... 169 Electrical System....................................................... 169 Safety Precautions Maintenance and Repair............................... 170 General................................................................. 173 Instrument Panels....................................................... 174 Standard Display.................................................... 176 Premium Display..................................................... 177 Replace............................................................. 177 Control and Power Fuses................................................. 178 Steer Angle Potentiometer............................................... 179 General............................................................. 179 Operation........................................................... 179 Install............................................................. 179 Positioning Steer Tire for Straight Travel.......................... 181 Adjust.............................................................. 181 Handset Method.................................................. 181 Voltmeter Method................................................ 182 Testing............................................................. 183 Power Steering Control Assembly......................................... 184 General............................................................. 184 Operation........................................................... 184 Testing............................................................. 185 Remove and Replace.................................................. 187 Power Steering Control Assembly................................. 187 Optical Encoder................................................. 187 Lift Pump Control Board................................................. 188 Testing............................................................. 195 Bypassing Lift Pump Control Board............................... 198 Sensor Interface/Contactor Driver Module................................ 198 General............................................................. 198 Troubleshooting..................................................... 200 Other Control Components................................................ 201 Key Switch.......................................................... 202 Seat Switch......................................................... 202 Replace......................................................... 202 Parking Brake Switch................................................ 203 Check........................................................... 203 Replace......................................................... 204 Accelerator Switch Assembly......................................... 204 Check........................................................... 205 Replace......................................................... 205 Direction Switches ( MONOTROL Pedal)................................ 205 Check........................................................... 205 Replace......................................................... 205 Direction Switches (Steering Column)................................ 206 Check........................................................... 206 Replace......................................................... 206 Brake Fluid Switch.................................................. 206 Hydraulic Cutoff Switch............................................. 207 Check........................................................... 207 Replace......................................................... 207 Stop Light Switch................................................... 208 Check........................................................... 208 Replace......................................................... 208 Motor Temperature Switches.......................................... 208 Rocker Switches for Lights.......................................... 208 DC-to-DC Converter.................................................. 209 Backup Light Relay Panel............................................ 210 Backup Light Switch Relay........................................... 210 Horn and Horn Button................................................ 210 Horn, Replace................................................... 210 Horn Button, Replace............................................ 211 Lights and Reverse Alarm............................................ 212 Light Assemblies Replacement............................................ 214 Tail Light.......................................................... 214 Flashing Light Assembly............................................. 214 Front Driving Light and Rear Work Light Assemblies.................. 216 Spot Light Assembly................................................. 216 tables...................................................................... 169 Table 1. Potentiometer Specifications................................... 183 Table 2. Power Steering Control Assembly Specifications................. 186 Table 3. Lift Pump Control Board Test Point/Function Relationshi........ 195 Table 4. Lift Pump Control Board Troubleshooting Guide.................. 196 Table 5. Lift Pump Control Board Test Values............................ 197 Table 6. Lift Pump Control Board Bypass Test............................ 198 Table 7. SICDM Connections/Descriptions/Status Codes.................... 199 Electrical System............................................................... 221 toc......................................................................... 221 Electrical System....................................................... 221 Safety Precautions Maintenance and Repair............................... 222 General................................................................. 225 Instrument Panels....................................................... 226 Standard Display.................................................... 228 Premium Display..................................................... 229 Replace............................................................. 229 Control and Power Fuses................................................. 230 Steer Angle Potentiometer............................................... 231 General............................................................. 231 Operation........................................................... 231 Install............................................................. 231 Positioning Steer Tire for Straight Travel.......................... 233 Adjust.............................................................. 233 Handset Method.................................................. 233 Voltmeter Method................................................ 234 Testing............................................................. 235 Power Steering Control Assembly......................................... 236 General............................................................. 236 Operation........................................................... 236 Testing............................................................. 237 Remove and Replace.................................................. 239 Power Steering Control Assembly................................. 239 Optical Encoder................................................. 239 Lift Pump Control Board................................................. 240 Testing............................................................. 247 Bypassing Lift Pump Control Board............................... 250 Sensor Interface/Contactor Driver Module................................ 250 General............................................................. 250 Troubleshooting..................................................... 252 Other Control Components................................................ 253 Key Switch.......................................................... 254 Seat Switch......................................................... 254 Replace......................................................... 254 Parking Brake Switch................................................ 255 Check........................................................... 255 Replace......................................................... 256 Accelerator Switch Assembly......................................... 256 Check........................................................... 257 Replace......................................................... 257 Direction Switches ( MONOTROL Pedal)................................ 257 Check........................................................... 257 Replace......................................................... 257 Direction Switches (Steering Column)................................ 258 Check........................................................... 258 Replace......................................................... 258 Brake Fluid Switch.................................................. 258 Hydraulic Cutoff Switch............................................. 259 Check........................................................... 259 Replace......................................................... 259 Stop Light Switch................................................... 260 Check........................................................... 260 Replace......................................................... 260 Motor Temperature Switches.......................................... 260 Rocker Switches for Lights.......................................... 260 DC-to-DC Converter.................................................. 261 Backup Light Relay Panel............................................ 262 Backup Light Switch Relay........................................... 262 Horn and Horn Button................................................ 262 Horn, Replace................................................... 262 Horn Button, Replace............................................ 263 Lights and Reverse Alarm............................................ 264 Light Assemblies Replacement............................................ 266 Tail Light.......................................................... 266 Flashing Light Assembly............................................. 266 Front Driving Light and Rear Work Light Assemblies.................. 268 Spot Light Assembly................................................. 268 tables...................................................................... 221 Table 1. Potentiometer Specifications................................... 235 Table 2. Power Steering Control Assembly Specifications................. 238 Table 3. Lift Pump Control Board Test Point/Function Relationshi........ 247 Table 4. Lift Pump Control Board Troubleshooting Guide.................. 248 Table 5. Lift Pump Control Board Test Values............................ 249 Table 6. Lift Pump Control Board Bypass Test............................ 250 Table 7. SICDM Connections/Descriptions/Status Codes.................... 251 Frame (1)....................................................................... 273 toc......................................................................... 273 Frame................................................................... 273 Safety Precautions Maintenance and Repair............................... 274 General................................................................. 277 Description............................................................. 277 Overhead Guard Repair................................................... 279 Remove.............................................................. 279 Install............................................................. 280 Hood and Seat Assembly Repair........................................... 280 Remove.............................................................. 281 Install............................................................. 281 Counterweight Repair.................................................... 282 Remove.............................................................. 282 Install............................................................. 283 Hydraulic Tank Repair................................................... 283 Inspect............................................................. 283 Small Leaks, Repair................................................. 283 Large Leaks, Repair................................................. 283 Clean............................................................... 284 Steam Method.................................................... 284 Chemical Solution Method........................................ 284 Additional Preparations for Repair.................................. 285 Safety Labels........................................................... 285 Battery Specifications.................................................. 287 tables...................................................................... 273 Table 1. Battery Platform Weights....................................... 282 Table 2. J30XMT2 Truck Capacity 1600 kg ( 3500 lb) - Wheel Base ........ 287 Table 3. J35XMT2 Truck Capacity 1800 kg ( 4000 lb) - Wheel Base ........ 288 Table 4. J40XMT2 Truck Capacity 2000 kg ( 4400 lb) - Wheel Base ........ 288 Frame........................................................................... 291 toc......................................................................... 291 Frame................................................................... 291 Safety Precautions Maintenance and Repair............................... 292 General................................................................. 295 Description............................................................. 295 Overhead Guard Repair................................................... 297 Remove.............................................................. 297 Install............................................................. 298 Hood and Seat Assembly Repair........................................... 298 Remove.............................................................. 299 Install............................................................. 299 Counterweight Repair.................................................... 300 Remove.............................................................. 300 Install............................................................. 301 Hydraulic Tank Repair................................................... 301 Inspect............................................................. 301 Small Leaks, Repair................................................. 301 Large Leaks, Repair................................................. 301 Clean............................................................... 302 Steam Method.................................................... 302 Chemical Solution Method........................................ 302 Additional Preparations for Repair.................................. 303 Safety Labels........................................................... 303 Battery Specifications.................................................. 305 tables...................................................................... 291 Table 1. Battery Platform Weights....................................... 300 Table 2. J30XMT2 Truck Capacity 1600 kg ( 3500 lb) - Wheel Base ........ 305 Table 3. J35XMT2 Truck Capacity 1800 kg ( 4000 lb) - Wheel Base ........ 306 Table 4. J40XMT2 Truck Capacity 2000 kg ( 4400 lb) - Wheel Base ........ 306 Husco Valve (1)................................................................. 309 toc......................................................................... 309 HUSCO™ Main Control Valve............................................... 309 Safety Precautions Maintenance and Repair............................... 310 General................................................................. 313 Description............................................................. 313 Operation............................................................... 313 Lift Section........................................................ 316 Tilt Section........................................................ 316 Tilt Backward................................................... 316 Tilt Forward.................................................... 316 Relief Valve........................................................ 318 Main Control Valve Repair............................................... 319 Remove.............................................................. 319 Disassemble......................................................... 324 Clean and Inspect................................................... 324 Assemble............................................................ 324 Install............................................................. 324 Pressure Relief Valve Check and Adjustment.............................. 327 Primary Relief Valve................................................ 327 Secondary Relief Valve.............................................. 327 Vane Settings Adjustment................................................ 328 Troubleshooting......................................................... 328 Husco Valve..................................................................... 333 toc......................................................................... 333 HUSCO™ Main Control Valve............................................... 333 Safety Precautions Maintenance and Repair............................... 334 General................................................................. 337 Description............................................................. 337 Operation............................................................... 337 Lift Section........................................................ 340 Tilt Section........................................................ 340 Tilt Backward................................................... 340 Tilt Forward.................................................... 340 Relief Valve........................................................ 342 Main Control Valve Repair............................................... 343 Remove.............................................................. 343 Disassemble......................................................... 348 Clean and Inspect................................................... 348 Assemble............................................................ 348 Install............................................................. 348 Pressure Relief Valve Check and Adjustment.............................. 351 Primary Relief Valve................................................ 351 Secondary Relief Valve.............................................. 351 Vane Settings Adjustment................................................ 352 Troubleshooting......................................................... 352 PM (1).......................................................................... 357 toc......................................................................... 357 Periodic Maintenance.................................................... 357 Safety Precautions Maintenance and Repair............................... 358 General................................................................. 361 How to Move Disabled Lift Truck..................................... 361 How to Tow Lift Truck........................................... 361 How to Put Lift Truck on Blocks..................................... 362 How to Raise Drive Tires........................................ 362 How to Raise Steer Tires........................................ 363 Maintenance Schedule.................................................... 364 Maintenance Procedures Every 8 Hours or Daily........................... 368 Before Operation Checks............................................. 368 Hydraulic System................................................ 368 Battery......................................................... 369 Battery Restraint System........................................ 369 Tires and Wheels................................................ 370 Safety Procedures When Working Near Mast............................ 371 Forks........................................................... 373 Adjust...................................................... 373 Remove...................................................... 374 Inspect..................................................... 374 Install..................................................... 374 Mast and Lift Chains............................................ 375 Lift Chain, Adjustment.......................................... 376 Operation Check..................................................... 377 Gauges and Horn................................................. 377 Control Levers and Pedals....................................... 377 Service Brakes.................................................. 377 Parking Brake................................................... 377 Steering System................................................. 377 Maintenance Procedures Every 350 Hours or 3 Months...................... 378 Hydraulic Tank Breather............................................. 378 Wheel Nut Torque.................................................... 378 Steering Actuator Mounting Bolts.................................... 378 Transaxle........................................................... 378 Lift System Operation............................................... 379 Mast................................................................ 379 Lift Chains......................................................... 381 Forks............................................................... 382 Safety Labels....................................................... 382 Brake Fluid......................................................... 382 Other Lubrication................................................... 382 Electrical Inspection............................................... 382 Special Precautions............................................. 382 Contactors...................................................... 383 Motor Brushes................................................... 383 Parking Brake................................................... 384 Maintenance Procedures Every 2000 Hours or Yearly....................... 390 Hydraulic System.................................................... 390 Hydraulic Oil Filter, Change.................................... 390 Hydraulic Oil Strainer, Check................................... 390 Hydraulic Oil, Change........................................... 390 Brakes.............................................................. 391 Parking Brake, Adjust........................................... 391 Transaxle........................................................... 391 Maintenance Procedures Every 4000 Hours................................. 393 Transaxle........................................................... 393 Lift and Tilt System Leak Check......................................... 393 Lift System......................................................... 393 Tilt System......................................................... 394 Battery Maintenance..................................................... 394 How to Charge Battery............................................... 394 How to Change Battery............................................... 395 Battery Size Specifications......................................... 396 Wheels and Tires Maintenance............................................ 398 General............................................................. 398 How to Change Tires................................................. 398 Steer and Drive Wheels.............................................. 398 Pneumatic Tires..................................................... 398 Remove Wheel From Lift Truck.................................... 398 Tire Sizes and Pressures........................................ 399 Remove Tire From Wheel.......................................... 400 Install Tire on Wheel........................................... 401 Add Air to Tires................................................ 402 Pneumatic-Shaped Solid Tires........................................ 402 Remove Wheel From Lift Truck.................................... 402 Press Tire From Wheel........................................... 403 Install Tire on Wheel........................................... 404 Install Wheel and Tire.............................................. 406 tables...................................................................... 357 Table 1. Maintenance Schedule........................................... 365 Table 2. Transaxle Specifications....................................... 392 Table 3. Battery Size Specifications - Type: Lead-Acid Battery.......... 396 PM.............................................................................. 409 toc......................................................................... 409 Periodic Maintenance.................................................... 409 Safety Precautions Maintenance and Repair............................... 410 General................................................................. 413 How to Move Disabled Lift Truck..................................... 413 How to Tow Lift Truck........................................... 413 How to Put Lift Truck on Blocks..................................... 414 How to Raise Drive Tires........................................ 414 How to Raise Steer Tires........................................ 415 Maintenance Schedule.................................................... 416 Maintenance Procedures Every 8 Hours or Daily........................... 420 Before Operation Checks............................................. 420 Hydraulic System................................................ 420 Battery......................................................... 421 Battery Restraint System........................................ 421 Tires and Wheels................................................ 422 Safety Procedures When Working Near Mast............................ 423 Forks........................................................... 425 Adjust...................................................... 425 Remove...................................................... 426 Inspect..................................................... 426 Install..................................................... 426 Mast and Lift Chains............................................ 427 Lift Chain, Adjustment.......................................... 428 Operation Check..................................................... 429 Gauges and Horn................................................. 429 Control Levers and Pedals....................................... 429 Service Brakes.................................................. 429 Parking Brake................................................... 429 Steering System................................................. 429 Maintenance Procedures Every 350 Hours or 3 Months...................... 430 Hydraulic Tank Breather............................................. 430 Wheel Nut Torque.................................................... 430 Steering Actuator Mounting Bolts.................................... 430 Transaxle........................................................... 430 Lift System Operation............................................... 431 Mast................................................................ 431 Lift Chains......................................................... 433 Forks............................................................... 434 Safety Labels....................................................... 434 Brake Fluid......................................................... 434 Other Lubrication................................................... 434 Electrical Inspection............................................... 434 Special Precautions............................................. 434 Contactors...................................................... 435 Motor Brushes................................................... 435 Parking Brake................................................... 436 Maintenance Procedures Every 2000 Hours or Yearly....................... 442 Hydraulic System.................................................... 442 Hydraulic Oil Filter, Change.................................... 442 Hydraulic Oil Strainer, Check................................... 442 Hydraulic Oil, Change........................................... 442 Brakes.............................................................. 443 Parking Brake, Adjust........................................... 443 Transaxle........................................................... 443 Maintenance Procedures Every 4000 Hours................................. 445 Transaxle........................................................... 445 Lift and Tilt System Leak Check......................................... 445 Lift System......................................................... 445 Tilt System......................................................... 446 Battery Maintenance..................................................... 446 How to Charge Battery............................................... 446 How to Change Battery............................................... 447 Battery Size Specifications......................................... 448 Wheels and Tires Maintenance............................................ 450 General............................................................. 450 How to Change Tires................................................. 450 Steer and Drive Wheels.............................................. 450 Pneumatic Tires..................................................... 450 Remove Wheel From Lift Truck.................................... 450 Tire Sizes and Pressures........................................ 451 Remove Tire From Wheel.......................................... 452 Install Tire on Wheel........................................... 453 Add Air to Tires................................................ 454 Pneumatic-Shaped Solid Tires........................................ 454 Remove Wheel From Lift Truck.................................... 454 Press Tire From Wheel........................................... 455 Install Tire on Wheel........................................... 456 Install Wheel and Tire.............................................. 458 tables...................................................................... 409 Table 1. Maintenance Schedule........................................... 417 Table 2. Transaxle Specifications....................................... 444 Table 3. Battery Size Specifications - Type: Lead-Acid Battery.......... 448 SEM Gen 1 (1)................................................................... 461 toc......................................................................... 461 SX/SR Transistor Motor Controllers and Handset.......................... 461 Safety Precautions Maintenance and Repair............................... 462 Introduction to SEM..................................................... 465 Advantages of Transistorized SEM.................................... 465 Features of SEM..................................................... 466 Solid-State Reversing........................................... 466 Performance and Efficiency...................................... 466 Field Weakening................................................. 466 Regenerative Braking............................................ 466 SX Transistor Motor Controllers......................................... 467 Introduction........................................................ 467 Proportional Operation for Dual-Motor Trucks........................ 467 General......................................................... 467 Operation....................................................... 469 Controller Features................................................. 471 General......................................................... 471 Creep Speed..................................................... 471 Controlled Acceleration......................................... 471 Current Limit................................................... 471 Braking............................................................. 471 Regenerative Braking to Zero Speed.............................. 471 Pedal Position Braking.......................................... 472 Auto Braking.................................................... 472 Conventional Plug Braking....................................... 472 Auxiliary Speed Control............................................. 472 Field Weakening................................................. 472 Speed Limits.................................................... 472 Ramp Operation...................................................... 472 Ramp Start...................................................... 472 Antirollback.................................................... 473 Steer Pump Contactor Time Delay..................................... 473 On-Board Coil Drivers and Internal Coil Suppression................. 473 System Protective Override.......................................... 473 SRO (Static Return to Off)...................................... 473 Accelerator Volts Hold Off...................................... 473 Pulse Monitor Trip (PMT)........................................ 473 Thermal Protector (TP).......................................... 473 Low Voltage..................................................... 473 SR Lift Pump Controllers................................................ 474 Sensor Interface/Contactor Driver Module................................ 478 Diagnostic Status Codes and Troubleshooting............................. 478 General Maintenance Instructions.................................... 478 Special Precautions............................................. 478 Diagnostics......................................................... 479 Systems Diagnostics............................................. 479 Status Codes........................................................ 479 Standard Status Codes........................................... 479 Stored Status Codes............................................. 480 Other Features...................................................... 480 Hourmeter Readings.............................................. 480 Maintenance Alert and Speed Limit............................... 480 Battery Discharge Indication (BDI).............................. 480 Internal Resistance Compensation................................ 480 Handset Programmable............................................ 480 RS 232 Communication Ports...................................... 480 Circuit Board Coil Driver Modules............................... 480 Maintenance Management Capability............................... 480 Interactive Instrument Panel Modes.............................. 481 General Troubleshooting Instructions................................ 483 Status Code Troubleshooting Tables...................................... 485 SX/SR Handset Instructions.............................................. 523 General Features.................................................... 523 Connecting the Handset.............................................. 525 Startup Sequence.................................................... 525 Setup Mode.......................................................... 526 Stored Status Code Mode............................................. 527 Clearing the Stored Status Codes.................................... 527 Restarting Lift Truck............................................... 527 SX Traction Controller Function Descriptions............................ 528 Premium Instrument Panel Interactive Modes.......................... 535 SR Pump Controller Function Descriptions................................ 538 Premium Instrument Panel Interactive Modes.......................... 540 tables...................................................................... 461 Table 1. SX Traction Controller Connections/Descriptions................ 468 Table 2. SR Lift Pump Controller Connections/Descriptions/Status........ 475 Table 3. Instrument Panel Function Number Correlation................... 481 Table 4. Traction Function Settings Logic............................... 482 Table 5. Lift Pump Function Settings Logic.............................. 483 Table 6. Speed/Torque Compensation...................................... 540 Table 7. Traction Controller Settings - Standard With Auto Regen........ 542 Table 8. Traction Controller Settings - Standard Without Auto Re........ 544 Table 9. Traction Controller Settings - High Performance With Au........ 545 Table 10. Lift Pump Controller Settings................................. 547 SEM Gen 1....................................................................... 551 toc......................................................................... 551 SX/SR Transistor Motor Controllers and Handset.......................... 551 Safety Precautions Maintenance and Repair............................... 552 Introduction to SEM..................................................... 555 Advantages of Transistorized SEM.................................... 555 Features of SEM..................................................... 556 Solid-State Reversing........................................... 556 Performance and Efficiency...................................... 556 Field Weakening................................................. 556 Regenerative Braking............................................ 556 SX Transistor Motor Controllers......................................... 557 Introduction........................................................ 557 Proportional Operation for Dual-Motor Trucks........................ 557 General......................................................... 557 Operation....................................................... 559 Controller Features................................................. 561 General......................................................... 561 Creep Speed..................................................... 561 Controlled Acceleration......................................... 561 Current Limit................................................... 561 Braking............................................................. 561 Regenerative Braking to Zero Speed.............................. 561 Pedal Position Braking.......................................... 562 Auto Braking.................................................... 562 Conventional Plug Braking....................................... 562 Auxiliary Speed Control............................................. 562 Field Weakening................................................. 562 Speed Limits.................................................... 562 Ramp Operation...................................................... 562 Ramp Start...................................................... 562 Antirollback.................................................... 563 Steer Pump Contactor Time Delay..................................... 563 On-Board Coil Drivers and Internal Coil Suppression................. 563 System Protective Override.......................................... 563 SRO (Static Return to Off)...................................... 563 Accelerator Volts Hold Off...................................... 563 Pulse Monitor Trip (PMT)........................................ 563 Thermal Protector (TP).......................................... 563 Low Voltage..................................................... 563 SR Lift Pump Controllers................................................ 564 Sensor Interface/Contactor Driver Module................................ 568 Diagnostic Status Codes and Troubleshooting............................. 568 General Maintenance Instructions.................................... 568 Special Precautions............................................. 568 Diagnostics......................................................... 569 Systems Diagnostics............................................. 569 Status Codes........................................................ 569 Standard Status Codes........................................... 569 Stored Status Codes............................................. 570 Other Features...................................................... 570 Hourmeter Readings.............................................. 570 Maintenance Alert and Speed Limit............................... 570 Battery Discharge Indication (BDI).............................. 570 Internal Resistance Compensation................................ 570 Handset Programmable............................................ 570 RS 232 Communication Ports...................................... 570 Circuit Board Coil Driver Modules............................... 570 Maintenance Management Capability............................... 570 Interactive Instrument Panel Modes.............................. 571 General Troubleshooting Instructions................................ 573 Status Code Troubleshooting Tables...................................... 575 SX/SR Handset Instructions.............................................. 613 General Features.................................................... 613 Connecting the Handset.............................................. 615 Startup Sequence.................................................... 615 Setup Mode.......................................................... 616 Stored Status Code Mode............................................. 617 Clearing the Stored Status Codes.................................... 617 Restarting Lift Truck............................................... 617 SX Traction Controller Function Descriptions............................ 618 Premium Instrument Panel Interactive Modes.......................... 625 SR Pump Controller Function Descriptions................................ 628 Premium Instrument Panel Interactive Modes.......................... 630 tables...................................................................... 551 Table 1. SX Traction Controller Connections/Descriptions................ 558 Table 2. SR Lift Pump Controller Connections/Descriptions/Status........ 565 Table 3. Instrument Panel Function Number Correlation................... 571 Table 4. Traction Function Settings Logic............................... 572 Table 5. Lift Pump Function Settings Logic.............................. 573 Table 6. Speed/Torque Compensation...................................... 630 Table 7. Traction Controller Settings - Standard With Auto Regen........ 632 Table 8. Traction Controller Settings - Standard Without Auto Re........ 634 Table 9. Traction Controller Settings - High Performance With Au........ 635 Table 10. Lift Pump Controller Settings................................. 637 SEM Gen II (1).................................................................. 641 toc......................................................................... 641 SR/SP Transistor Motor Controller and Handset........................... 641 Safety Precautions Maintenance and Repair............................... 642 Introduction to SEM..................................................... 645 Advantages of Transistorized SEM.................................... 645 Features of SEM..................................................... 645 Solid-State Reversing........................................... 645 Performance and Efficiency...................................... 645 Field Weakening................................................. 645 Regenerative Braking............................................ 645 SR Transistor Traction Motor Controllers................................ 646 Introduction........................................................ 646 Proportional Operation for Dual-Motor Trucks........................ 646 General......................................................... 646 Operation....................................................... 648 Controller Features................................................. 650 General......................................................... 650 Creep Speed..................................................... 650 Controlled Acceleration......................................... 650 Current Limit................................................... 650 Braking............................................................. 650 Regenerative Braking to Zero Speed.............................. 650 Pedal Position Braking.......................................... 650 Auto Regenerative Braking....................................... 651 Conventional Plug Braking....................................... 651 Auxiliary Speed Control............................................. 651 Field Weakening................................................. 651 Speed Limits.................................................... 651 Ramp Operation...................................................... 651 Ramp Start...................................................... 651 Antirollback.................................................... 651 Steer Pump Contactor Time Delay..................................... 652 On-Board Coil Drivers and Internal Coil Suppression................. 652 System Protective Override.......................................... 652 SRO (Static Return to Off)...................................... 652 Accelerator Volts Hold Off...................................... 652 Pulse Monitor Trip (PMT)........................................ 652 Thermal Protector (TP).......................................... 652 Low Voltage..................................................... 652 SP Lift Pump Controllers................................................ 653 Sensor Interface/Contactor Driver Module................................ 657 Diagnostic Status Codes and Troubleshooting............................. 657 General Maintenance Instructions.................................... 657 Special Precautions............................................. 657 Diagnostics......................................................... 658 Systems Diagnostics............................................. 658 Status Codes........................................................ 658 Standard Status Codes........................................... 658 Stored Status Codes............................................. 659 Other Features...................................................... 659 Hourmeter Readings.............................................. 659 Maintenance Alert and Speed Limit............................... 659 Battery Discharge Indication (BDI).............................. 659 Internal Resistance Compensation................................ 659 Handset Programmable............................................ 659 RS 232 Communication Ports...................................... 660 Circuit Board Coil Driver Modules............................... 660 Maintenance Management Capability............................... 660 Interactive Instrument Panel Modes (Premium Only)............... 660 General Troubleshooting Instructions................................ 663 Status Code Troubleshooting Tables...................................... 664 Description......................................................... 664 SR/SP Handset Instructions.............................................. 705 General Features.................................................... 705 Connecting Handset.................................................. 707 Startup Sequence.................................................... 708 Setup Mode.......................................................... 708 Stored Status Code Mode............................................. 708 Clearing Stored Status Codes........................................ 710 Restarting Lift Truck............................................... 710 SR Traction Controller Function Descriptions............................ 710 Premium Instrument Panel Interactive Modes.......................... 717 SP Pump Controller Function Descriptions................................ 720 Premium Instrument Panel Interactive Modes.......................... 723 tables...................................................................... 641 Table 1. SR Traction Controller Connections/Descriptions................ 647 Table 2. SP Lift Pump Controller Connections/Descriptions/Status........ 654 Table 3. Instrument Panel Function Number Correlation................... 661 Table 4. Traction Function Settings Logic............................... 662 Table 5. Lift Pump Function Settings Logic.............................. 663 Table 6. Speed/Torque Compensation...................................... 722 SEM Gen II...................................................................... 727 toc......................................................................... 727 SR/SP Transistor Motor Controller and Handset........................... 727 Safety Precautions Maintenance and Repair............................... 728 Introduction to SEM..................................................... 731 Advantages of Transistorized SEM.................................... 731 Features of SEM..................................................... 731 Solid-State Reversing........................................... 731 Performance and Efficiency...................................... 731 Field Weakening................................................. 731 Regenerative Braking............................................ 731 SR Transistor Traction Motor Controllers................................ 732 Introduction........................................................ 732 Proportional Operation for Dual-Motor Trucks........................ 732 General......................................................... 732 Operation....................................................... 734 Controller Features................................................. 736 General......................................................... 736 Creep Speed..................................................... 736 Controlled Acceleration......................................... 736 Current Limit................................................... 736 Braking............................................................. 736 Regenerative Braking to Zero Speed.............................. 736 Pedal Position Braking.......................................... 736 Auto Regenerative Braking....................................... 737 Conventional Plug Braking....................................... 737 Auxiliary Speed Control............................................. 737 Field Weakening................................................. 737 Speed Limits.................................................... 737 Ramp Operation...................................................... 737 Ramp Start...................................................... 737 Antirollback.................................................... 737 Steer Pump Contactor Time Delay..................................... 738 On-Board Coil Drivers and Internal Coil Suppression................. 738 System Protective Override.......................................... 738 SRO (Static Return to Off)...................................... 738 Accelerator Volts Hold Off...................................... 738 Pulse Monitor Trip (PMT)........................................ 738 Thermal Protector (TP).......................................... 738 Low Voltage..................................................... 738 SP Lift Pump Controllers................................................ 739 Sensor Interface/Contactor Driver Module................................ 743 Diagnostic Status Codes and Troubleshooting............................. 743 General Maintenance Instructions.................................... 743 Special Precautions............................................. 743 Diagnostics......................................................... 744 Systems Diagnostics............................................. 744 Status Codes........................................................ 744 Standard Status Codes........................................... 744 Stored Status Codes............................................. 745 Other Features...................................................... 745 Hourmeter Readings.............................................. 745 Maintenance Alert and Speed Limit............................... 745 Battery Discharge Indication (BDI).............................. 745 Internal Resistance Compensation................................ 745 Handset Programmable............................................ 745 RS 232 Communication Ports...................................... 746 Circuit Board Coil Driver Modules............................... 746 Maintenance Management Capability............................... 746 Interactive Instrument Panel Modes (Premium Only)............... 746 General Troubleshooting Instructions................................ 749 Status Code Troubleshooting Tables...................................... 750 Description......................................................... 750 SR/SP Handset Instructions.............................................. 791 General Features.................................................... 791 Connecting Handset.................................................. 793 Startup Sequence.................................................... 794 Setup Mode.......................................................... 794 Stored Status Code Mode............................................. 794 Clearing Stored Status Codes........................................ 796 Restarting Lift Truck............................................... 796 SR Traction Controller Function Descriptions............................ 796 Premium Instrument Panel Interactive Modes.......................... 803 SP Pump Controller Function Descriptions................................ 806 Premium Instrument Panel Interactive Modes.......................... 809 tables...................................................................... 727 Table 1. SR Traction Controller Connections/Descriptions................ 733 Table 2. SP Lift Pump Controller Connections/Descriptions/Status........ 740 Table 3. Instrument Panel Function Number Correlation................... 747 Table 4. Traction Function Settings Logic............................... 748 Table 5. Lift Pump Function Settings Logic.............................. 749 Table 6. Speed/Torque Compensation...................................... 808 Specs (1)....................................................................... 813 toc......................................................................... 813 Capacities and Specifications........................................... 813 Safety Precautions Maintenance and Repair............................... 814 Wheels and Tires........................................................ 817 Motors (Dual Voltage 36/48)............................................. 817 Mast Tilt Performance................................................... 817 Mast Speeds............................................................. 818 Contactor Controlled 19cc/rev Displacement Pump..................... 818 Transistor Controlled 19cc/rev Displacement Pump.................... 819 Contactor Controlled 12cc Displacement Pump......................... 820 Transistor Controlled 12cc/rev Displacement Pump.................... 821 Mast/Tilt Drift Speeds.............................................. 822 Hydraulic System........................................................ 822 Transaxle Specifications................................................ 822 Torque Specifications................................................... 823 Frame............................................................... 823 Transaxle........................................................... 823 Brake System........................................................ 823 Wheels.............................................................. 823 Steering System..................................................... 823 Hydraulic System.................................................... 823 Mast/Tilt/Attachment Systems........................................ 824 Accelerator Potentiometer Checks........................................ 824 Controller Settings..................................................... 824 SR/SP Traction Controller Settings - Standard....................... 824 SR/SP Traction Controller Settings - 36 V Energy Saver Option....... 826 SR/SP Traction Controller Settings - With or Without Auto Decele.... 826 SR/SP Traction Controller Settings - With or Without Lift Limit..... 826 SR/SP Lift Pump Controller Settings................................. 827 Battery Size Specifications............................................. 828 Type: Lead Acid Battery............................................. 828 Specs........................................................................... 833 toc......................................................................... 833 Capacities and Specifications........................................... 833 Safety Precautions Maintenance and Repair............................... 834 Wheels and Tires........................................................ 837 Motors (Dual Voltage 36/48)............................................. 837 Mast Tilt Performance................................................... 837 Mast Speeds............................................................. 838 Contactor Controlled 19cc/rev Displacement Pump..................... 838 Transistor Controlled 19cc/rev Displacement Pump.................... 839 Contactor Controlled 12cc Displacement Pump......................... 840 Transistor Controlled 12cc/rev Displacement Pump.................... 841 Mast/Tilt Drift Speeds.............................................. 842 Hydraulic System........................................................ 842 Transaxle Specifications................................................ 842 Torque Specifications................................................... 843 Frame............................................................... 843 Transaxle........................................................... 843 Brake System........................................................ 843 Wheels.............................................................. 843 Steering System..................................................... 843 Hydraulic System.................................................... 843 Mast/Tilt/Attachment Systems........................................ 844 Accelerator Potentiometer Checks........................................ 844 Controller Settings..................................................... 844 SR/SP Traction Controller Settings - Standard....................... 844 SR/SP Traction Controller Settings - 36 V Energy Saver Option....... 846 SR/SP Traction Controller Settings - With or Without Auto Decele.... 846 SR/SP Traction Controller Settings - With or Without Lift Limit..... 846 SR/SP Lift Pump Controller Settings................................. 847 Battery Size Specifications............................................. 848 Type: Lead Acid Battery............................................. 848 Steering (1).................................................................... 853 toc......................................................................... 853 Steering System......................................................... 853 Safety Precautions Maintenance and Repair............................... 854 General................................................................. 857 Operation............................................................... 857 Steering Wheel and Column Assembly...................................... 858 Description......................................................... 858 Remove.............................................................. 858 Install............................................................. 861 Power Steering Pump and Motor........................................... 862 Description......................................................... 862 Remove.............................................................. 862 Install............................................................. 864 Disassemble......................................................... 864 Assemble............................................................ 865 Steering Axle Components................................................ 866 General............................................................. 866 Wheel and Tire Assembly............................................. 866 Remove.......................................................... 866 Install......................................................... 866 Wheel Hub Assembly.................................................. 866 Remove.......................................................... 866 Install......................................................... 867 Steering Axle Assembly.............................................. 867 Remove.......................................................... 867 Clean........................................................... 868 Install......................................................... 868 Steering System Air Removal............................................. 870 Operation Check......................................................... 870 Steering Pressure Check................................................. 871 Troubleshooting......................................................... 871 Steering........................................................................ 879 toc......................................................................... 879 Steering System......................................................... 879 Safety Precautions Maintenance and Repair............................... 880 General................................................................. 883 Operation............................................................... 883 Steering Wheel and Column Assembly...................................... 884 Description......................................................... 884 Remove.............................................................. 884 Install............................................................. 887 Power Steering Pump and Motor........................................... 888 Description......................................................... 888 Remove.............................................................. 888 Install............................................................. 890 Disassemble......................................................... 890 Assemble............................................................ 891 Steering Axle Components................................................ 892 General............................................................. 892 Wheel and Tire Assembly............................................. 892 Remove.......................................................... 892 Install......................................................... 892 Wheel Hub Assembly.................................................. 892 Remove.......................................................... 892 Install......................................................... 893 Steering Axle Assembly.............................................. 893 Remove.......................................................... 893 Clean........................................................... 894 Install......................................................... 894 Steering System Air Removal............................................. 896 Operation Check......................................................... 896 Steering Pressure Check................................................. 897 Troubleshooting......................................................... 897 Transaxle (1)................................................................... 905 toc......................................................................... 905 Transaxle............................................................... 905 Safety Precautions Maintenance and Repair............................... 906 General................................................................. 909 Lubrication............................................................. 910 Transaxle Repair........................................................ 910 Remove.............................................................. 910 Inspect............................................................. 911 Install............................................................. 911 S2 Series Transaxle..................................................... 912 Disassemble......................................................... 912 Inspection.......................................................... 913 Assemble............................................................ 913 General......................................................... 913 Ring Gear, Install.............................................. 913 Intermediate Shaft, Install..................................... 913 Axle Shaft, Install............................................. 916 Pinion Gear, Install............................................ 916 Final Assembly.................................................. 920 S1 Series Transaxle..................................................... 921 Disassemble......................................................... 921 Assemble............................................................ 921 Troubleshooting......................................................... 924 tables...................................................................... 905 Table 1. Transaxle Identification....................................... 909 Table 2. Transaxle Specifications....................................... 909 Table 3. Gear Teeth Contact Pattern..................................... 919 Transaxle....................................................................... 927 toc......................................................................... 927 Transaxle............................................................... 927 Safety Precautions Maintenance and Repair............................... 928 General................................................................. 931 Lubrication............................................................. 932 Transaxle Repair........................................................ 932 Remove.............................................................. 932 Inspect............................................................. 933 Install............................................................. 933 S2 Series Transaxle..................................................... 934 Disassemble......................................................... 934 Inspection.......................................................... 935 Assemble............................................................ 935 General......................................................... 935 Ring Gear, Install.............................................. 935 Intermediate Shaft, Install..................................... 935 Axle Shaft, Install............................................. 938 Pinion Gear, Install............................................ 938 Final Assembly.................................................. 942 S1 Series Transaxle..................................................... 943 Disassemble......................................................... 943 Assemble............................................................ 943 Troubleshooting......................................................... 946 tables...................................................................... 927 Table 1. Transaxle Identification....................................... 931 Table 2. Transaxle Specifications....................................... 931 Table 3. Gear Teeth Contact Pattern..................................... 941 Troubleshooting w pc (1)........................................................ 949 ............................................................................ 949 ............................................................................ 950 ............................................................................ 951 ............................................................................ 952 ............................................................................ 953 ............................................................................ 954 ............................................................................ 955 ............................................................................ 956 ............................................................................ 957 ............................................................................ 958 ............................................................................ 959 ............................................................................ 960 ............................................................................ 961 ............................................................................ 962 ............................................................................ 963 ............................................................................ 964 ............................................................................ 965 ............................................................................ 966 ............................................................................ 967 ............................................................................ 968 Troubleshooting w pc windows (1)................................................ 969 toc......................................................................... 969 Troubleshooting and Adjustments With a Computer......................... 969 Safety Precautions Maintenance and Repair............................... 970 Computer System......................................................... 973 Connect a PC to a Control Card...................................... 974 Installation........................................................ 975 HYTECH™ Windows Software Program........................................ 975 How to Start the Program............................................ 975 DEMO Mode........................................................... 976 Selecting the Communications Port................................... 978 Verification of Controller and Lift Truck........................... 979 Select Lift Truck Series............................................ 981 Controller Card Register Parameter List............................. 982 How to Change a Parameter........................................... 983 How to Save a Changed Parameter File................................ 984 How to Load a Saved Parameter File.................................. 985 How to Show and Remove Saved Parameter Files........................ 986 How to Return to Factory Default Settings........................... 987 How to Save Changes to Control Card................................. 988 How to View Status Codes............................................ 989 Saving Status Codes................................................. 990 How to Show and Remove Saved Status Code Files...................... 992 Closing and Clearing Status Code List............................... 992 How to View Saved Register Data and Saved Status Data............... 993 How to Save Register Data and Status Code Data In .RTF and .TXT .... 995 GE Sentry™ Software Program............................................. 996 Installation........................................................ 996 Description......................................................... 996 How to Start GE SENTRY Program...................................... 996 How to Reset MIN and MAX Display....................................1001 Graphing Mode.......................................................1002 How to Exit GE SENTRY Program.......................................1003 tables...................................................................... 969 Table 1. Cable Connections - Computer to Control........................ 973 Table 2. Adapter Pins (DB25F to DB9).................................... 973 Table 3. Plug-Z Connection.............................................. 974 Troubleshooting w pc windows....................................................1007 toc.........................................................................1007 Troubleshooting and Adjustments With a Computer.........................1007 Safety Precautions Maintenance and Repair...............................1008 Computer System.........................................................1011 Connect a PC to a Control Card......................................1012 Installation........................................................1013 HYTECH™ Windows Software Program........................................1013 How to Start the Program............................................1013 DEMO Mode...........................................................1014 Selecting the Communications Port...................................1016 Verification of Controller and Lift Truck...........................1017 Select Lift Truck Series............................................1019 Controller Card Register Parameter List.............................1020 How to Change a Parameter...........................................1021 How to Save a Changed Parameter File................................1022 How to Load a Saved Parameter File..................................1023 How to Show and Remove Saved Parameter Files........................1024 How to Return to Factory Default Settings...........................1025 How to Save Changes to Control Card.................................1026 How to View Status Codes............................................1027 Saving Status Codes.................................................1028 How to Show and Remove Saved Status Code Files......................1030 Closing and Clearing Status Code List...............................1030 How to View Saved Register Data and Saved Status Data...............1031 How to Save Register Data and Status Code Data In .RTF and .TXT ....1033 GE Sentry™ Software Program.............................................1034 Installation........................................................1034 Description.........................................................1034 How to Start GE SENTRY Program......................................1034 How to Reset MIN and MAX Display....................................1039 Graphing Mode.......................................................1040 How to Exit GE SENTRY Program.......................................1041 tables......................................................................1007 Table 1. Cable Connections - Computer to Control........................1011 Table 2. Adapter Pins (DB25F to DB9)....................................1011 Table 3. Plug-Z Connection..............................................1012 Troubleshooting w pc............................................................1045 ............................................................................1045 ............................................................................1046 ............................................................................1047 ............................................................................1048 ............................................................................1049 ............................................................................1050 ............................................................................1051 ............................................................................1052 ............................................................................1053 ............................................................................1054 ............................................................................1055 ............................................................................1056 ............................................................................1057 ............................................................................1058 ............................................................................1059 ............................................................................1060 ............................................................................1061 ............................................................................1062 ............................................................................1063 ............................................................................1064 Unlock-Steering Hydraulics (1)..................................................1065 Unlock-Steering Hydraulics......................................................1077
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